This manual covers the 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, and 200 EXC models produced between 1999 and 2003. The brand is renowned for its off-road motorcycle expertise, and these models represent a strong offering in the 125cc and 200cc categories, building upon their competitive heritage. These liquid-cooled, 2-stroke motorcycles are engineered for performance and durability in demanding off-road conditions. This comprehensive workshop repair service manual provides detailed, step-by-step procedures for all aspects of maintenance, repair, and troubleshooting. It includes in-depth coverage of the engine top end, fuel and cooling systems, clutch, lubrication, crankshaft and transmission, wheels, tires, final drive, brakes, suspension, steering, frame, and electrical system, complete with wiring diagrams. The manual is designed to empower owners and technicians with the knowledge to maintain vehicle reliability and performance, offering significant savings on repair costs. 🏷️ Basic Information Identification Make: KTM Model: 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC Model Years Covered: 1999, 2000, 2001, 2002, 2003 Engine Variants Covered: 125cc, 200cc (specific displacements not detailed in provided info, but implied by model names) Codes Platform Codes: Not specified in product information Generation Generation Designation: Third Generation (for SX/MXC models), Pre-Generation 3 for EXC models (as per typical KTM nomenclature for this era) 👋 Introduction Market Position Target Audience: KTM owners seeking DIY maintenance and repair, independent workshops Competitive Analysis Advantages: Comprehensive coverage, official manufacturer data, digital convenience, cost savings potential Key Features Benefit 1: Save significant repair costs Benefit 2: Maintain vehicle reliability and performance Benefit 3: Empower users with professional-level diagnostic and repair knowledge Format Advantage: Print specific sections as needed, keeping digital copy clean 📋 Manual Details Coverage Areas Primary Coverage: All Models/Engines/Trim/Transmissions Types Specific Models: KTM 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC Page Count Estimated Page Count: Hundreds of pages (as stated in description) Manual Type Type: Workshop Repair Service Manual Source: Original Manufacturer (KTM) Language Language: English Format Format: PDF Download Delivery Method: Instant Download Requirements: Adobe PDF Reader, WinZip Compatibility: All Versions of Windows & Mac 📖 Manual Coverage Systems Covered Engine Top End: Included Fuel System: Included Cooling System: Included Clutch: Included Lubrication System: Included Crankshaft Transmission: Included Wheels Tires: Included Final Drive: Included Brakes: Included Suspension: Included Steering: Included Frame: Included Electrical System: Included (with wiring diagrams) General Information: Included Appendix: Included Procedures Included Maintenance: Included (detailed) Troubleshooting: Included Repair Procedures: Included (step-by-step, detailed substeps) Disassembly: Included Assembly: Included Cleaning: Included Reinstallation: Included Diagnostics: Included (comprehensive) Electrical Service: Included (combined with wiring diagrams) Technical Depth Depth: Complete Professional Technician Level Content Quality: Top Quality, Complete, Intact 📊 Manual Specifications File Format Type: PDF Print Quality Printability: Full Printable Zoom Functionality: Zoom IN/OUT capability Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Features Illustrations: Detailed diagrams, drawings, and photos Instructions: Numbered, step-by-step, easy-to-follow Critical Information: Notes, cautions, warnings Identification Aid: Bold figure numbers to match illustrations Part Identification: Enlarged inset views for detailed part examination Navigation: Numbered table of contents for fast information retrieval ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder (typical for this era and models) Bore Stroke 125: Specific values not provided in product description. Likely around 54mm x 54.5mm based on historical data for 125cc KTM 2-strokes. Bore Stroke 200: Specific values not provided in product description. Likely around 62.5mm x 65mm based on historical data for 200cc KTM 2-strokes. Cooling System: Liquid-cooled Performance Horsepower 125: Estimated 30-35 HP (varies by model variant - SX, EXC, MXC), specific figures not in description. Horsepower 200: Estimated 35-40 HP (varies by model variant), specific figures not in description. Fuel System Carburetor Type: Keihin PWK (common for this era, specific size not listed) Fuel Type: Unleaded gasoline with 2-stroke oil pre-mix (specified in manual) Engine Management Ignition System: CDI (Capacitor Discharge Ignition) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Hydraulically operated, multi-disc wet clutch Features Gear Ratios: Specific ratios not provided, but detailed within the manual. Transmission Fluid Type: Manual will specify SAE 10W/30 or 10W/40 transmission oil (specific OEM or aftermarket recommendations to be found in manual). 📐 Dimensions Exterior Wheelbase: Varies by model (SX/MXC/EXC), specific figures not provided. Weights Dry Weight: Approximately 90-100 kg (varies by model), specific figures not provided. 💡 Technology Features Infotainment Infotainment System: N/A (These are performance off-road motorcycles with minimal rider-focused technology beyond essential functions). Driver Assistance Driver Assistance Features: N/A Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Intervals for engine oil and gearbox oil will be specified in the manual, typically requiring frequent checks and changes for performance off-road bikes. Spark Plug Replacement: Specific intervals will be detailed, dependent on usage and spark plug type. Air Filter Cleaning: Frequent cleaning and re-oiling are critical for off-road...