🏷️ Basic Information Identification Make: KTM Model: 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC Model Variant: Sportmotorcycles Year: 1999, 2000, 2001, 2002, 2003 Engine Type: 2-Stroke Codes Manual Code: Not Specified (Factory Service Manual) 👋 Introduction Market Position Category: Off-road Competition Motorcycles (Motocross, Enduro, Supermoto) Target Audience: Owners and technicians of KTM 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, and 200 EXC motorcycles from model years 1999-2003. Competitive Analysis Competitors 1999 2003: Yamaha YZ125, YZ250 (for 2-stroke comparisons), Honda CR125R, CR250R, Suzuki RM125, RM250, Kawasaki KX125, KX250. In the EXC/MXC segment, competitors would include Enduro-focused models from these brands as well as Husaberg and Husqvarna. Key Features Manual Value: Authoritative, factory-backed repair and maintenance information for a specific range of performance off-road motorcycles, crucial for proper upkeep and longevity. Vehicle Characteristics: Lightweight, agile, potent 2-stroke engines, race-bred chassis, designed for demanding off-road conditions. 📋 Manual Details Coverage Areas Manual Type: Factory Service / Repair / Workshop Manual Language: English Format: PDF (Instant Download) Page Count: Not Specified (typical for factory service manuals, often extensive) 📖 Manual Coverage Systems Covered Engine Systems: Engine disassembly, assembly, internal components (piston, rings, cylinder, crankshaft, connecting rod), cylinder head, valves (where applicable for 4-stroke variants not explicitly covered here but standard manual scope), lubrication system, cooling system (liquid cooling for these models), fuel system (carburetor, fuel lines), ignition system, exhaust system. Transmission Systems: Clutch, gearbox (transmission gears, shifting mechanisms), final drive (chain and sprockets inspection and adjustment). Chassis Systems: Frame inspection and repair, suspension (forks, rear shock absorber, linkages), steering system, wheels and hubs, brake systems (front and rear), electrical system (wiring diagrams, lighting, ignition components, battery, charging system), bodywork and plastics. Procedures Included Maintenance: Routine inspections, oil changes, filter replacements, chain adjustment, spark plug replacement, coolant checks and changes, brake pad replacement, general lubrication, pre-ride checks. Repair: Engine rebuilds, transmission overhaul, suspension servicing, brake caliper and master cylinder repair, electrical component troubleshooting and replacement, carburetor tuning and repair, body panel replacement. Troubleshooting: Diagnostic procedures for common starting issues, running problems, electrical faults, cooling system issues, braking performance problems, and suspension behavior. Technical Data: Torque specifications for all fasteners, engine clearances, valve adjustments (if applicable to the specific model variants covered), wiring schematics, fluid capacities, component specifications. Technical Depth Depth: Comprehensive: Covers from basic maintenance and fluid checks to complete engine and transmission rebuilds, in-depth electrical troubleshooting, and chassis component overhauls. Suitable for experienced DIY mechanics and professional workshop use. 📊 Manual Specifications File Format File Type: PDF Searchable: Likely searchable text within the PDF for efficient information retrieval. Printable: Designed to be printable, allowing users to create physical copies for workshop use. Print Quality: High-resolution, ensuring clarity of diagrams, illustrations, and text. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, 2-stroke, liquid-cooled Bore X Stroke 125: 54.0 mm x 54.5 mm (approximate, subject to specific model year variations) Bore X Stroke 200: 62.5 mm x 54.5 mm (approximate, subject to specific model year variations) Displacement 125: 124.8 cc Displacement 200: 199.8 cc Ignition: Digital CDI (Capacitive Discharge Ignition) Performance Power Output 125: Approx. 35-40 HP (at crankshaft, highly dependent on model and tuning) Power Output 200: Approx. 40-45 HP (at crankshaft, highly dependent on model and tuning) Torque: Specific torque figures are model-dependent, but generally strong for their displacement in the mid-range. Fuel System Carburetor: Keihin PWK series (e.g., PWK 38 AS, or similar, specific size varies by model) Fuel Type: Unleaded gasoline (min. 95 RON/91 AKI) mixed with 2-stroke oil (premix or oil injection depending on specific model) Premix Ratio: Typically 1:30 to 1:50 (2-stroke oil to gasoline), consult manual for exact recommendation. Cooling System: Liquid-cooled with radiator and fan. Maintenance Items Spark Plug 125: NGK BR8EG or equivalent (specific recommendation in manual) Spark Plug 200: NGK BR8EG or equivalent (specific recommendation in manual) 🔧 Transmission Standard Type: Constant mesh, sequential manual transmission Number Of Gears: 6-speed Clutch: Hydraulically operated, multi-plate wet clutch Gear Ratios: Specific gear ratios are model and year dependent and detailed in the manual. Transmission Oil Type: Specific motorcycle gearbox oil (e.g., Motorex Gear Oil 75W/80 or equivalent API GL-4 specification) Transmission Oil Capacity: Approx. 0.7 - 0.8 liters (refer to manual for exact capacity) Features Clutch Actuation: Self-adjusting hydraulic system for consistent lever feel and minimal maintenance. 📐 Dimensions Exterior Frame Type: Chromium-molybdenum steel central double-cradle frame. Suspension Front: WP USD (Upside Down) telescopic forks. Specific travel and adjustment capabilities vary by model (e.g., SX: 275-300mm, EXC: 295-300mm). Suspension Rear: WP monoshock with linkage system (PDS – Power Differential System for EXC, or similar linkage for SX). Specific travel varies (e.g., SX: 300-320mm, EXC: 320-330mm). Wheelbase: Typically around 1445-1470 mm, varying slightly by model and year. Ground Clearance: Approx....