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KTM 125 200 SX MXC EXC 1999 Repair Service Manual

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$16.99
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$16.99
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This manual provides comprehensive service and repair information for the 1999 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, and 200 EXC models. These performance-oriented off-road motorcycles are...
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类型: Motorcycle
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斯库: 57853
KTM 125 200 SX MXC EXC 1999 Repair Service ManualKTM 125 200 SX MXC EXC 1999 Repair Service ManualKTM 125 200 SX MXC EXC 1999 Repair Service ManualKTM 125 200 SX MXC EXC 1999 Repair Service Manual
This manual provides comprehensive service and repair information for the 1999 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, and 200 EXC models. These performance-oriented off-road motorcycles are renowned for their potent two-stroke engines, advanced suspension systems, and agile handling, making them highly competitive in motocross, cross-country, and enduro disciplines. The commitment to a 'Ready to Race' philosophy is evident in these machines, which were engineered for demanding off-road conditions and built upon a strong racing heritage. The 125cc and 200cc variants offer distinct power delivery characteristics, with the larger displacement providing a noticeable torque advantage, all within a lightweight and robust chassis designed for rider control and durability. The scope of this repair service manual is extensive, covering all essential aspects required for maintaining and repairing your motorcycle. It includes detailed procedures for engine overhaul, transmission service, suspension maintenance, brake system servicing, and electrical system diagnostics. Within its pages, you will find guidance on routine maintenance, troubleshooting common issues, and in-depth information on component rebuilds, including carburetors and suspension units. The manual is structured to assist both novice owners performing basic upkeep and professional technicians undertaking complex repairs, ensuring the optimal performance and longevity of your 1999 125 or 200cc off-road machine.
🏷️ Basic Information
Identification
Make:
KTM
Model:
125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC
Year:
1999
Codes
Chassis Codes:
Likely 2-stroke specific chassis designations based on model variant (e.g., EXC for Enduro, SX for Motocross). Specific codes not provided in product info.
Engine Codes:
Likely variations of KTM's 125cc and 200cc 2-stroke single-cylinder engines. Specific codes not provided in product info.
👋 Introduction
Market Position
Segment:
Performance Off-Road Motorcycles (Motocross, Enduro, Cross-Country)
Target Audience:
Enthusiast owners, amateur racers, professional mechanics, and service workshops specializing in off-road KTM motorcycles.
Competitive Analysis
Competitors 1999:
Yamaha YZ125/250, Honda CR125R/250R, Suzuki RM125/250, Kawasaki KX125/250, Husqvarna CR/WR 125/250.
Ktm Advantage 1999:
KTM in 1999 was establishing a strong reputation for competitive performance, particularly in European markets, with a focus on powerful, agile, and durable off-road machinery. The 125/200cc two-strokes were known for their potent powerbands and handling.
Key Features
Engine Type:
2-stroke single-cylinder, liquid-cooled (likely, particularly for EXC models).
Suspension Type:
High-quality performance suspension systems, typically from WP Suspension, known for adjustability and damping capabilities.
Design Focus:
Competition-oriented design prioritizing power-to-weight ratio, handling agility, and rider control for demanding off-road conditions.
📋 Manual Details
Coverage Areas
Primary Coverage:
Repair and Service for KTM 125 and 200 models (SX, MXC, EXC variants)
Model Variants Covered:
125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC
Page Count
Estimated Page Count:
Typically 300-500 pages for comprehensive service manuals of this era, but not explicitly stated in product info.
Manual Type
Manual Type:
Repair Service Manual
Language
Language:
Likely English, but not explicitly stated in product info.
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Service:
Full engine overhaul, disassembly, assembly, timing, carburetor tuning, piston/ring replacement, cylinder head service, crankcase maintenance, cooling system (if applicable for the era/model).
Transmission Service:
Clutch operation, gearbox disassembly and assembly, gear shifting mechanisms, transmission fluid changes and specifications.
Suspension Service:
Front fork (WP, Marzocchi, or similar) maintenance, seal replacement, oil levels and specifications. Rear shock absorber service, linkage lubrication, adjustment procedures.
Brake System:
Hydraulic brake system service (front and rear), brake fluid types and bleeding procedures, caliper overhaul, pad replacement, rotor inspection.
Electrical System:
Ignition system troubleshooting, stator and rotor specifications, lighting circuits, wiring diagrams, battery maintenance and specifications.
Fuel System:
Fuel tank inspection and cleaning, fuel line maintenance, carburetor model identification, jetting charts (often model/altitude specific), air filter service.
Cooling System:
For liquid-cooled variants (likely on EXC models), coolant type and capacity, radiator inspection, water pump service.
Chassis And Frame:
Frame inspection, swingarm maintenance, bearing checks and lubrication, footpeg and control lever adjustments.
Wheel And Tire:
Wheel bearing inspection and replacement, spoke tensioning, tire pressure recommendations, rim strip and tube maintenance.
Procedures Included
Routine Maintenance:
Oil changes, air filter cleaning/replacement, spark plug inspection/replacement, chain adjustment and lubrication, brake pad checks.
Troubleshooting Guides:
Diagnostic procedures for common starting issues, performance problems, electrical faults, and mechanical failures.
Engine Rebuilds:
Detailed steps for complete engine teardown, component inspection, parts replacement (piston, rings, seals, bearings), and reassembly.
Suspension Overhaul:
Front fork seal and bushing replacement, rear shock absorber seal head replacement, tuning adjustments.
Carburetor Rebuilding:
Carburetor disassembly, cleaning, jet replacement, float bowl adjustment, and reassembly.
Electrical Diagnostics:
Using wiring diagrams to diagnose ignition, lighting, and charging system faults.
Specific Model Variations:
Distinctions between SX (Motocross), MXC (Cross-Country), and EXC (Enduro) models regarding suspension, gearing, and other specifications.
Technical Depth
Diagnostic Level:
Advanced diagnostics for engine performance, electrical systems, and mechanical components.
Repair Scope:
Comprehensive repair procedures for major and minor component overhauls and replacements.
Expert Orientation:
Prepared primarily for professional technicians, indicating a high level of technical detail and assumed knowledge.
📊 Manual Specifications
File Format
File Format:
PDF
Searchability:
Typically PDF manuals offer text search capabilities, enhancing usability for locating specific information.
Print Quality
Print Quality:
Dependent on source, but digital PDFs are generally sharp and clear for printing.
Binding Type
Binding Type:
N/A (Digital Download)
Paper Type
Paper Type:
N/A (Digital Download)
Completeness
Completeness:
Assumed to be a complete service manual covering all aspects of repair and maintenance for the specified models.
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke single-cylinder, piston-ported (likely).
Displacement 125:
Approximately 124-125 cc.
Displacement 200:
Approximately 193-200 cc.
Bore X Stroke 125:
Common bore/stroke for 125cc 2-strokes of this era (e.g., around 54mm x 54.5mm), but exact figures require manual confirmation.
Bore X Stroke 200:
Common bore/stroke for 200cc 2-strokes of this era (e.g., around 62.5mm x 65mm), but exact figures require manual confirmation.
Cooling System:
Likely Liquid-Cooled (especially for EXC/MXC, some SX models might be air-cooled depending on specific sub-variant).
Performance
Horsepower 125:
Estimated 30-35 HP at the crank, depending on specific tuning and model variant.
Horsepower 200:
Estimated 35-40 HP at the crank, offering a notable torque advantage over the 125.
Torque Delivery:
Characterized by a strong mid-range to top-end powerband, typical of performance 2-strokes.
Fuel System
Carburetor Type:
Likely Keihin PWK or similar high-performance carburetor (e.g., 36-38mm).
Fuel Type:
Unleaded gasoline with a specific octane rating (e.g., 95-98 RON), plus 2-stroke oil pre-mix (ratio specified in manual).
🔧 Transmission
Standard
Type:
6-speed constant mesh sequential gearbox.
Clutch Type:
Wet multi-plate clutch, hydraulically actuated.
Features
Gear Ratios:
Specific gear ratios vary between SX, MXC, and EXC models and are detailed in the manual.
Final Drive:
Chain drive (e.g., 520 pitch).
📐 Dimensions
Exterior
Ground Clearance:
Varies by model, but typically high for off-road use, around 350-380mm.
Seat Height:
Varies by model, typically around 950-980mm.
Weights
Dry Weight 125:
Approximately 90-95 kg (dry).
Dry Weight 200:
Approximately 95-100 kg (dry).
🛡️ Safety Features
Ratings
Crash Safety:
Not applicable in the same manner as street vehicles; designed for off-road durability and rider protection.
Active Features
Braking System:
Hydraulic disc brakes front and rear, typically with Brembo components known for their stopping power and feel.
Passive Features
Frame Construction:
Chromoly steel perimeter frame providing rigidity and impact resistance.
Ergonomics:
Designed for optimal rider control and fatigue reduction in off-road conditions.
💡 Technology Features
Infotainment
Infotainment System:
N/A - These are performance off-road motorcycles with no infotainment features.
Driver Assistance
Driver Assistance Features:
N/A - No driver assistance systems are present.
Connectivity
Connectivity Features:
N/A - No connectivity features.
🔧 Maintenance
Service Intervals
Oil Change Frequency:
Varies based on usage (racing vs. recreational), but typically every 10-15 hours of operation for gearbox oil.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions, often after every few rides.
Spark Plug Replacement:
Inspection every 20-30 hours, replacement as needed based on condition.
Top End Rebuild:
Piston and ring replacement recommended around 50-100 hours of aggressive use, depending on riding style and maintenance.
Fluid Specifications
Engine Oil Type:
Specific 2-stroke premix oil recommended by KTM (e.g., Motorex or equivalent high-performance synthetic 2T oil).
Gearbox Oil Type:
Specific transmission oil (e.g., SAE 75W/80W or 10W/40 depending on KTM's recommendation for that year, likely a dedicated motorcycle gearbox oil).
Coolant Type:
Ethylene glycol based coolant, 50/50 mix with distilled water (for liquid-cooled models).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Common Wear Items:
Clutch plates, piston rings, wheel bearings, fork seals, chain and sprockets.
Potential Failures:
Overheating (if cooling system maintenance is neglected), ignition coil failure, crankcase bearing wear over high mileage.
📚 Vehicle History
Brand Heritage
Ktm History:
KTM, an Austrian manufacturer, has a long and storied history in off-road motorcycle racing and production, known for its 'Ready to Race' philosophy.
Model Evolution
125 200Cc Lineage:
KTM has consistently produced competitive 125cc and later 200cc two-stroke engines for motocross, enduro, and cross-country racing throughout the 1980s and 1990s. The 1999 models represent a development in their competitive platform, featuring updated chassis and suspension.
Production
Manufacturing Location:
Austria (primarily for core components and assembly).
🏆 Awards & Recognition
Recognitions
Racing Success:
KTM's 125 and 200cc platforms have historically been successful in various off-road racing disciplines, contributing to their reputation and market appeal.
Ratings
Performance Reviews:
Contemporary reviews for KTM models of this era often praised their powerful engines, advanced suspension, and agile handling, positioning them as top-tier competitive machinery.
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