This manual covers the 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, and 200 EXC models from the 2002 model year. These performance-oriented off-road motorcycles are renowned for their potent two-stroke engines, robust chassis, and exceptional handling capabilities, embodying a 'Ready to Race' philosophy. The SX variants are designed for motocross, the MXC for cross-country racing, and the EXC for enduro and dual-sport applications. Their engineering prioritizes agility, power delivery, and durability in demanding off-road conditions, making them highly competitive machines. This comprehensive English-language repair and service manual provides in-depth technical guidance for maintaining and repairing these models. It covers all essential systems, including detailed procedures for engine disassembly and assembly, transmission servicing, suspension maintenance, brake system upkeep, and electrical system diagnostics. The manual also includes routine maintenance tasks, troubleshooting guides for common issues, and critical technical specifications such as torque values and clearances. Its purpose is to serve as an authoritative resource for professional technicians and experienced owners alike, ensuring the optimal performance and longevity of their motorcycles. 🏷️ Basic Information Identification Make: KTM Model: 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC Year: 2002 👋 Introduction Market Position Target Audience: Primarily professional KTM technicians and experienced home mechanics working on 2002 KTM SX, MXC, and EXC models. Competitive Analysis Value Proposition: Provides comprehensive, in-depth technical guidance essential for maintaining and repairing these performance-oriented off-road motorcycles. Key Features Coverage Breadth: Covers a wide range of models within the 125cc and 200cc displacement classes for the 2002 model year, addressing both competition and dual-sport variants. 📋 Manual Details Coverage Areas Language: English Manual Type: Repair and Service Manual Format: PDF Download Page Count Estimated Pages: Approximately 300-400 pages (estimated based on typical coverage for these models). 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, troubleshooting, and maintenance for 125cc and 200cc two-stroke engines. Transmission: Complete service procedures for the gearbox, clutch, and shifting mechanisms. Suspension: Fork and shock absorber servicing, including seal replacement, oil changes, and valving adjustments. Brakes: Hydraulic brake system maintenance, including bleeding, pad replacement, and caliper service. Electrical: Wiring diagrams, ignition system troubleshooting, lighting, and charging system service. Fuel System: Carburetor tuning, cleaning, and jetting; fuel tank and line maintenance. Cooling System: Radiator and coolant system maintenance (where applicable for specific EXC/MXC models). Chassis: Frame inspection, steering head bearing service, and swingarm maintenance. Bodywork: Fairing, seat, and plastics removal and installation procedures. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning. Troubleshooting: Systematic diagnostic procedures for common issues like starting problems, poor running, and electrical faults. Engine Rebuild: Detailed steps for top-end and bottom-end engine overhauls, including piston, ring, cylinder, crankshaft, and bearing replacement. Suspension Rebuild: Complete procedures for servicing front forks and rear shock absorbers, including sealhead replacement and damper rod service. Brake Service: Master cylinder, caliper, and line maintenance, including bleeding procedures. Carburetor Overhaul: Complete disassembly, cleaning, inspection, and reassembly of Keihin carburetors. Electrical Diagnostics: Troubleshooting ignition, lighting, and charging circuits using wiring diagrams. Technical Depth Diagnostic Capabilities: Advanced diagnostic routines and fault code interpretation (where applicable for the era). Repair Complexity: Covers basic maintenance to full engine and transmission rebuilds. Precision Requirements: Includes critical torque specifications, clearances, and assembly tolerances. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Readability: High-resolution scans for clear text and legible diagrams. Binding Type Digital Binding: N/A (Digital Download) Paper Type Digital Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Bore Stroke 125: 54 mm x 54.5 mm (approximate, verify with specific model data) Bore Stroke 200: 62.5 mm x 65 mm (approximate, verify with specific model data) Cooling: Liquid-cooled Ignition System: Digital CDI Power Delivery: Known for strong mid-range and top-end power delivery characteristic of KTM two-strokes. Performance Horsepower 125: Approximately 35-40 HP (estimated, model dependent) Horsepower 200: Approximately 40-45 HP (estimated, model dependent) Fuel System Carburetor Type: Keihin PWK (typically 35mm or 38mm, model dependent) Fuel Type: Unleaded gasoline with appropriate two-stroke oil pre-mix ratio (e.g., 50:1). 🔧 Transmission Standard Type: 6-speed constant mesh Features Clutch Type: Wet multi-plate clutch Gearbox Design: Robust KTM gearbox known for durability and precise shifting. 📐 Dimensions Exterior Chassis Type: Chromoly steel tubular frame Weights Dry Weight: Approx. 95-105 kg (209-231 lbs), model dependent 🛡️ Safety Features Ratings Off Road Focus: Designed for off-road competition and use, safety features are performance-oriented rather than road-legal compliance. Active Features Brakes: Hydraulic disc brakes (front and rear) for strong stopping power. Suspension Control: High-performance WP suspension provides stability and control over varied terrain. 💡 Technology Features Infotainment Features: Minimalist design focused on performance; typically lacks complex infotainment systems found on street bikes. Driver Assistance Features: No electronic driver assistance features typical of modern motorcycles; focus is on rider input and...