This manual covers the 125 XC, 200 XC, 125 XC-W, and 200 XC-W models produced between 1999 and 2006. These performance off-road motorcycles are renowned for their lightweight design, agile handling, and potent 2-stroke power delivery, making them highly competitive in motocross and enduro disciplines. Building on a strong off-road heritage, these models offer robust capability and a focus on rider control, characteristic of Austrian engineering. This comprehensive workshop repair service manual provides detailed guidance for maintaining and repairing your motorcycle. It covers all essential systems, including engine mechanicals, fuel and ignition systems, transmission, suspension, brakes, and the electrical system. You will find step-by-step procedures for routine maintenance, engine rebuilds, suspension overhauls, and troubleshooting common issues. This manual is an invaluable resource for owners and technicians aiming to ensure optimal performance and longevity of these off-road machines. 🏷️ Basic Information Identification Make: KTM Model: 125 XC, 200 XC, 125 XC-W, 200 XC-W Year: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Engine Variants: 125cc, 200cc (Specific engine codes not provided in product description, but generally single-cylinder, liquid-cooled, 2-stroke for this era and model designation.) Codes Chassis Codes: XC and XC-W designations typically indicate off-road, cross-country competition models. Specific chassis codes (e.g., EXC variants from which these might be derived) are not detailed but would be covered within the manual. 👋 Introduction Market Position Segment: Performance Off-Road Competition / Enduro Motorcycles Target Audience: Enthusiast riders, off-road racers, mechanics specializing in KTM off-road models. Competitive Analysis Competitors Era: Similar displacement models from Yamaha (YZ series), Honda (CR/CRE series), Suzuki (RM series), Kawasaki (KX series). Key Features Vehicle Strengths: Lightweight, agile handling, potent 2-stroke power delivery characteristic of KTM, robust off-road capability. Manual Value Proposition: Empowers owners to perform in-depth maintenance and repairs, saving time and money, ensuring optimal performance and longevity. 📋 Manual Details Coverage Areas Model Years Covered: 1999-2006 Models Covered: KTM 125 XC, KTM 200 XC, KTM 125 XC-W, KTM 200 XC-W Page Count Estimated Page Count: Variable, but typical workshop manuals for this scope range from 300-600+ pages depending on detail level. Manual Type Type: Workshop Repair Service Manual Language Language: English (Assumed based on product description and common industry practice for downloaded manuals.) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair for 125cc and 200cc 2-stroke engines. Includes cylinder head, piston, connecting rod, crankshaft, seals, gaskets, lubrication system, cooling system (radiator, water pump). Engine Tuning: Carburetor tuning, jetting recommendations, ignition timing adjustments (where applicable), exhaust system considerations. Fuel System: Fuel tank, fuel lines, fuel pump (if applicable), fuel filter, carburetor service and overhaul (e.g., Mikuni VM series common on these models). Ignition System: CDI unit, stator, ignition coil, spark plug, wiring diagrams related to ignition. Transmission Drivetrain: Clutch assembly (operation, adjustment, overhaul), gearbox (gear selection, shifting mechanism, bearings, seals), final drive (chain, sprockets, adjustment). Suspension Front: Front fork (telescopic), oil seals, bushings, spring rates, damping adjustments, service and rebuild procedures, fork stanchion condition. Suspension Rear: Monoshock rear suspension, linkage system (if applicable), shock absorber service and rebuild, spring adjustment, bearing checks. Brakes Front: Hydraulic disc brakes, caliper overhaul, master cylinder service, brake pads, brake lines, bleeding procedures, rotor specifications. Brakes Rear: Hydraulic disc brakes, caliper overhaul, master cylinder service, brake pads, brake lines, bleeding procedures, rotor specifications. Electrical System: Wiring diagrams, battery maintenance, lighting (headlight, taillight, brake light), horn, fuses, switches, starter system (if electric start equipped). Cooling System: Radiator, coolant hoses, thermostat (if applicable), coolant type and capacity, bleeding procedures. Frame Chassis: Frame inspection, steering head bearings, swingarm pivot bearings, wheel bearings, general chassis integrity checks. Bodywork: Seat removal, fuel tank removal/installation, fender removal/installation, plastics, graphics. Procedures Included Preventative Maintenance: Routine checks, lubrication points, air filter cleaning/replacement, spark plug inspection, chain adjustment and lubrication. Troubleshooting: Diagnostic guides for common starting problems, engine performance issues, electrical faults, braking issues, suspension behavior. Engine Rebuild: Step-by-step instructions for complete engine teardown, cleaning, inspection of components (e.g., piston ring gap, cylinder wear), and reassembly. Suspension Overhaul: Detailed guidance on replacing fork seals, bushings, and rebuilding rear shock absorbers. Brake System Maintenance: Pad replacement, caliper servicing, master cylinder rebuild, fluid flush and bleeding. Electrical Diagnostics: Testing of charging system, ignition components, and lighting circuits using multimeters and diagnostic procedures outlined in the manual. Carburetor Adjustment: Idle speed, air-fuel mixture, jetting changes for altitude or modifications. Torque Specifications: Precise torque values for critical fasteners throughout the motorcycle, crucial for safe and reliable assembly. Technical Depth Depth: Comprehensive coverage suitable for DIY enthusiasts and professional mechanics. Includes detailed schematics, diagnostic flowcharts, and precise measurements for wear limits and adjustments. 📊 Manual Specifications File Format Format: PDF Searchability: Searchable text content within the PDF for quick information retrieval. Print Quality Printability: Designed for printing specific sections or the entire manual for use in a workshop...