This manual covers the 125 and 200 models from the production years 1999 through 2003. These motorcycles are powered by a liquid-cooled, single-cylinder, four-stroke engine, available in 125cc and 200cc configurations. Known for their sporty performance and agile handling, these models embody a "Ready to Race" heritage, offering an engaging riding experience suitable for both spirited commuting and recreational use. Their robust engineering and accessible performance make them popular choices within their displacement categories. This comprehensive service and repair manual is designed to assist owners, mechanics, and technicians in maintaining and repairing the 125/200 series. It provides detailed procedures for routine maintenance, including oil changes, filter replacements, and chain adjustments, as well as in-depth guidance on engine overhauls, transmission and clutch servicing, and chassis and suspension maintenance. The manual also covers the electrical system, fuel system diagnostics, and brake system servicing, offering troubleshooting advice and essential technical specifications to ensure optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: KTM Model: 125 / 200 Engine Family: Liquid-cooled single-cylinder four-stroke Codes Engine Codes Covered: Likely refers to engines used in models such as Duke 125/200, RC 125/200, and potentially other regional variants for the specified years. 👋 Introduction Market Position Target Audience: DIY mechanics, independent repair shops, and KTM enthusiasts seeking to maintain and repair their 125 or 200cc motorcycles. Competitive Analysis Value Proposition: Provides essential technical data and procedures crucial for preserving the performance and longevity of these specific KTM models, often at a fraction of dealer service costs. Key Features Content Focus: Engine-centric repair and maintenance, reflecting the product name. However, a comprehensive service manual would also cover chassis and electrical aspects. 📋 Manual Details Coverage Areas Model Years: 1999, 2000, 2001, 2002, 2003 Engine Variants: 125cc and 200cc engine configurations. Page Count Estimated Pages: Varies based on specific manual content, but typically between 300-600 pages for a comprehensive service manual. Manual Type Type: Service and Repair Manual Language Language: English (assumed, standard for most widely distributed repair manuals unless specified otherwise) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, cylinder head, piston, crankshaft, connecting rod, valve train, timing, lubrication system, cooling system. Fuel System: Fuel injection system (if applicable to specific 125/200 variants of these years), carburetion (for older versions), fuel pump, fuel filter, injectors/carburetor tuning. Ignition System: CDI unit, spark plug, ignition coils, wiring. Transmission And Drivetrain: Gearbox, clutch assembly, shift mechanism, final drive (chain and sprockets). Electrical System: Wiring diagrams, battery, alternator, starter motor, lighting system, sensors, ECU (if applicable). Cooling System: Radiator, cooling fan, water pump, coolant hoses, thermostat. Chassis And Suspension: Front forks (including seals and oil), rear shock absorber, swingarm, bearings. Brakes: Front and rear brake systems, hydraulic lines, master cylinders, calipers, brake pads, brake fluid specifications. Exhaust System: Exhaust manifold, muffler, catalytic converter (if fitted). Procedures Included Routine Maintenance: Oil change intervals and specifications, filter replacement, chain adjustment, spark plug replacement, air filter cleaning/replacement. Troubleshooting: Diagnostic procedures for common starting, running, and performance issues; fault code interpretation (if applicable). Engine Rebuild: Detailed step-by-step instructions for engine disassembly, inspection, and reassembly, including torque specifications. Suspension Overhaul: Fork seal replacement, damper rod service, rear shock absorber maintenance. Clutch Adjustment And Replacement: Procedure for adjusting clutch cable and replacing clutch plates. Electrical Diagnostics: Testing of electrical components, wiring continuity checks, charging system diagnostics. Brake Bleeding: Correct procedure for bleeding brake systems. Technical Depth Level: Comprehensive; covers everything from basic rider maintenance to full engine and chassis overhauls, including detailed specifications and torque values. 📊 Manual Specifications File Format Quality: High-resolution PDF, typically scanned from original factory manuals, ensuring clarity of text and diagrams. Searchable: Likely searchable text, allowing quick access to specific information. Print Quality Recommendation: Printable on standard home or office printers for convenient workshop use. Binding Type Physical Manual Analogy: Equivalent to a professionally bound workshop manual, often spiral-bound or perfect-bound for lay-flat use. Paper Type Physical Manual Analogy: Contents are equivalent to those found on durable, high-quality paper stock suitable for workshop environments. ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, four-stroke, liquid-cooled Displacement: 125cc and 200cc variants Performance Typical Horsepower 125Cc: Approximately 15-17 hp (varies by region and specific model revision) Typical Horsepower 200Cc: Approximately 20-25 hp (varies by region and specific model revision) Bore X Stroke Approx 125Cc: Likely around 54mm x 54.5mm (requires confirmation from specific model) Bore X Stroke Approx 200Cc: Likely around 64mm x 58mm (requires confirmation from specific model) Fuel System Induction: Likely carburetor (e.g., Keihin CVK) or early fuel injection systems depending on the specific model and market. Manual will detail the specific system. Fuel Type: Unleaded gasoline, premium octane recommended. Engine Build Cooling: Liquid-cooled Valve Actuation: SOHC (Single Overhead Camshaft), likely 4 valves 🔧 Transmission Standard Type: 6-speed constant mesh, sequential manual gearbox Optional Variants: No automatic or...