This manual covers the 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, and 200 EXC models produced between 1999 and 2003. An Austrian manufacturer renowned for its off-road racing prowess, designed these motorcycles for competitive and recreational use, emphasizing performance and durability. Known for their sharp handling and potent engines relative to their displacement, these models reflect the 'Ready to Race' philosophy and have a strong heritage in motocross and enduro championships. This comprehensive service repair manual provides in-depth guidance for owners and technicians. It details routine maintenance, complete engine and chassis disassembly and assembly, troubleshooting procedures, and rebuilding instructions for critical components like the engine, transmission, and suspension. The manual includes essential technical specifications, torque values, and wiring diagrams, ensuring proper maintenance and repair to uphold the performance and longevity of your off-road motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC Product Type: Service Repair Manual Codes Engine Codes Implied: LC2 125, LC2 200 (specific codes depend on sub-model and exact year, typically an internal KTM designation) Chassis Codes Implied: SX (Motocross), MXC (Cross-Country/Enduro), EXC (Enduro) - specific chassis codes (e.g., EXC-F, SXS) may vary and are not explicitly detailed in the product name but are covered by the broad model designations. 👋 Introduction Market Position Target Audience: KTM owners, independent motorcycle repair shops, enthusiasts performing their own maintenance and repairs. Competitive Advantage Manual: Provides official, factory-level detail for a specific range of KTM off-road models, crucial for maintaining performance and longevity. Competitive Analysis Competitors To Manual: Haynes, Clymer manuals (often less detailed or based on general knowledge rather than factory data). Key Features Key Manual Features: Comprehensive engine rebuild procedures, detailed electrical diagrams, specific torque values, troubleshooting guides. 📋 Manual Details Coverage Areas Production Years Covered: 1999, 2000, 2001, 2002, 2003 Model Variants Covered: 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC Geographic Coverage: Global (assuming standard European/North American specifications for these models) Page Count Estimated Page Count: Estimated 300-500 pages (typical for comprehensive service manuals of this era) Manual Type Manual Type: Official Factory Service Repair Manual Language Language: English (Standard for most downloadable manuals, though original may have had multiple languages) Format Format: Downloadable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine teardown, assembly, rebuild, including cylinder, piston, crankshaft, connecting rod, bearings, seals, gaskets, valves (if applicable, though these are typically 2-stroke), lubrication system. Fuel System: Carburetor overhaul (Mikuni VM Series common), jetting, fuel lines, fuel tank. Ignition System: CDI ignition, stator, coil, spark plug specifications, timing. Exhaust System: Expansion chamber, muffler maintenance, mounting. Cooling System: Liquid cooling system maintenance (radiator, hoses, water pump, coolant specifications). Transmission: Gearbox disassembly and assembly, clutch operation (wet multi-plate), gear ratios, shift mechanism, transmission fluid type and capacity. Chassis Components: Frame inspection and repair, suspension (front forks - WPUSD/USD types common, rear shock - WP PDS common), steering system, swingarm, wheel bearings, linkage (if applicable). Brakes: Hydraulic disc brakes (front and rear), brake caliper service, master cylinder overhaul, brake fluid type (DOT 4 common), bleeding procedures. Electrical System: Wiring diagrams, battery maintenance, lighting, switches, fuses (if applicable to engine start/kill circuits). Procedures Included Routine Maintenance: Oil changes (gearbox), chain adjustment, air filter cleaning/replacement, spark plug checks, brake fluid checks, coolant level checks. Disassembly Assembly: Step-by-step instructions for complete engine and chassis component removal and installation. Troubleshooting: Diagnostic procedures for common performance issues, starting problems, and mechanical failures. Rebuilding: Detailed instructions for engine top-end and bottom-end rebuilds, carburetor rebuilds, suspension fork rebuilds. Torque Specifications: All critical fasteners and component torque values specified for proper assembly. Technical Depth Diagnostic Capability: Advanced diagnostics, including component testing and performance issue root cause analysis. Rebuild Depth: Complete motorcycle rebuild, from engine internals to chassis and suspension overhauls. Detail Level: Detailed exploded views, diagrams, and step-by-step instructions with specifications. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Typically searchable text within PDF for efficient information retrieval. Print Quality Print Quality: High-resolution scans suitable for printing, with clear diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type 125: Liquid-cooled, 2-stroke, single-cylinder (2-stroke power valve system typical) Bore Stroke 125: Approx. 54 mm x 54.5 mm (verify for specific model year variant within manual) Displacement 125: 125 cc (approximate, actual may vary slightly) Engine Type 200: Liquid-cooled, 2-stroke, single-cylinder (2-stroke power valve system typical) Bore Stroke 200: Approx. 64 mm x 62.5 mm (verify for specific model year variant within manual) Displacement 200: 200 cc (approximate, actual may vary slightly) Performance Horsepower 125: Approx. 30-35 HP (stock, varies by model variant and tuning) Horsepower 200: Approx. 35-40 HP (stock, varies by model variant and tuning) Fuel System Carburetor Type: Mikuni VM...