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KTM 125 200 SX SXS MXC 1999-2006 Service Repair Manual

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Basic Information Identification Make: KTM Model: 125 SX, 200 SX, 125 SXS, 200 SXS, 125 MXC, 200 MXC Production Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Vehicle Codes: N/A (Specific chassis codes not provided, but manual covers multiple variants within these model lines) Introduction Market Position Target Audience: KTM owners with basic mechanical skills, independent repair shops, and authorized dealer service departments. Competitive Analysis Value Proposition: Provides the same detailed technical information and procedures used by authorized dealers, enabling significant cost savings on maintenance and repairs. Key Features Content Quality: Accurate, clear, and concise text with diagrams, illustrations, wiring schematics, and specifications. Practicality: Enables owners to be better informed and to discuss repairs knowledgeably with technicians, or perform repairs themselves. Content Guarantee Completeness: States it is complete and intact without missing or corrupt parts/pages, and is vehicle-specific, not generic. Manual Details Coverage Areas Covered Models: KTM 125 SX, 200 SX, 125 SXS, 200 SXS, 125 MXC, 200 MXC Covered Years: 1999-2006 Page Count Estimated Page Count: Likely extensive, given the detailed subject matter. (Actual page count not specified, but typical service manuals for this era and scope are several hundred pages). Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: Engine specifications, removal/installation, fuel system, intake & exhaust, lubrication, cooling system, engine internal components (e.g., pistons, crankshafts, cylinders). Transmission: Transmission operation, maintenance, repair, and specifications. Drivetrain: Drive chain and sprockets maintenance, adjustment, and replacement. Electrical System: Wiring diagrams, electrical component testing, troubleshooting, ignition system, lighting. Suspension: Front forks (shocks) and rear shock absorber maintenance, adjustment, and repair. Steering: Steering system inspection, maintenance, and repair. Bodywork: Body panel removal, installation, and maintenance. Procedures Included Maintenance: Routine maintenance, periodic checks and adjustments, lubrication, fluid changes. Repair: Step-by-step repair instructions for all major systems, engine rebuilds, transmission overhauls. Troubleshooting: Advanced troubleshooting guides, diagnostic procedures for common and complex issues. Diagnostics: Detailed diagnostic procedures to identify faults and problems. Diagrams Illustrations: Includes step-by-step instructions with diagrams, illustrations, and wiring schematics for all repair and maintenance procedures. Technical Depth Depth: Comprehensive, covering everything from basic checks and fluid changes to full engine and transmission rebuilds. Includes detailed specifications and diagrams essential for professional-level repair. Manual Specifications File Format Format: PDF Compatibility: All versions of Windows and Mac Requirements: Adobe PDF Reader Download Speed: Advertised as 'Speed Download'. Print Quality Printability: Yes, all pages are printable. Clarity: Designed for clear viewing and printing of individual pages to avoid damage in a workshop environment. Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) Engine Specifications Primary Engine Type: 2-stroke, single-cylinder (for both 125 and 200 variants) Displacement 125Cc Variant: Approximately 125cc (Specific bore/stroke for the 125cc models). 200Cc Variant: Approximately 200cc (Specific bore/stroke for the 200cc models). Performance Horsepower Torque: Specific figures are detailed within the manual (typical for this era, performance-oriented motocross/off-road engines). Fuel System Carburetion: Likely Keihin or Mikuni carburetors (Specific models and jetting detailed in the manual). Fuel Type: Unleaded gasoline with appropriate octane rating (specified in manual). Cooling System Type: Liquid-cooled (Water-cooled via radiator and coolant). Lubrication Type: Pre-mix fuel/oil or oil injection system (details specific to model variants will be in manual). Transmission Standard Type: 6-speed manual transmission. Optional Options: N/A (Typically a single transmission option for specific models). Features Clutch: Hydraulic clutch actuation (common for KTMs of this era). Gear Ratios: Specific gear ratios for each gear are provided in the manual. Fluid Requirements Transmission Oil: Specific type and capacity (e.g., SAE 10W/50, API SG or higher) detailed in manual. Dimensions Exterior Overall Length: Varies by specific model (SX vs. MXC), but detailed in the manual. Wheelbase: Varies by specific model, detailed in the manual. Weights Dry Weight: KTM 125 SX typically around 90-95 kg (200-210 lbs), 200 models slightly more. Exact figures in manual. Tires Front Tire Size: Commonly 80/100-21 (details specific to SX/SXS/MXC variants in manual). Rear Tire Size: Commonly 100/90-19 or 110/90-19 (details specific to SX/SXS/MXC variants in manual). Wheels Wheel Type: Spoked wheels with aluminum rims. Safety Features Ratings Crash Test Results: N/A (Motocross/off-road motorcycles are not subject to standard automotive crash testing). Safety is focused on rider protection and vehicle dynamics. Active Features Braking System: Hydraulic disc brakes front and rear. Specific caliper and rotor sizes detailed in manual. Passive Features Frame Construction: Chromoly steel perimeter frame (known for strength and rigidity). Technology Features Infotainment Features: N/A (These are performance-oriented off-road motorcycles with minimal electronic amenities). Driver Assistance Features: N/A (No driver assistance features on these models). Engine Management Ignition System: CDI (Capacitor Discharge Ignition) or similar electronic ignition system. Tuning and troubleshooting covered. Power Valve: Details on the operation, adjustment, and maintenance of the mechanical power valve system. Maintenance Service Intervals Oil Change Frequency: Details for...
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SKU: 61427
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KTM 125 200 SX SXS MXC 1999-2006 Service Repair Manual
Basic Information
Identification
Make: KTM
Model: 125 SX, 200 SX, 125 SXS, 200 SXS, 125 MXC, 200 MXC
Production Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Codes
Vehicle Codes: N/A (Specific chassis codes not provided, but manual covers multiple variants within these model lines)
Introduction
Market Position
Target Audience: KTM owners with basic mechanical skills, independent repair shops, and authorized dealer service departments.
Competitive Analysis
Value Proposition: Provides the same detailed technical information and procedures used by authorized dealers, enabling significant cost savings on maintenance and repairs.
Key Features
Content Quality: Accurate, clear, and concise text with diagrams, illustrations, wiring schematics, and specifications.
Practicality: Enables owners to be better informed and to discuss repairs knowledgeably with technicians, or perform repairs themselves.
Content Guarantee
Completeness: States it is complete and intact without missing or corrupt parts/pages, and is vehicle-specific, not generic.
Manual Details
Coverage Areas
Covered Models: KTM 125 SX, 200 SX, 125 SXS, 200 SXS, 125 MXC, 200 MXC
Covered Years: 1999-2006
Page Count
Estimated Page Count: Likely extensive, given the detailed subject matter. (Actual page count not specified, but typical service manuals for this era and scope are several hundred pages).
Manual Type
Type: Service Repair Workshop Manual
Language
Language: English
Format
Format: PDF Download
Manual Coverage
Systems Covered
Engine: Engine specifications, removal/installation, fuel system, intake & exhaust, lubrication, cooling system, engine internal components (e.g., pistons, crankshafts, cylinders).
Transmission: Transmission operation, maintenance, repair, and specifications.
Drivetrain: Drive chain and sprockets maintenance, adjustment, and replacement.
Electrical System: Wiring diagrams, electrical component testing, troubleshooting, ignition system, lighting.
Suspension: Front forks (shocks) and rear shock absorber maintenance, adjustment, and repair.
Steering: Steering system inspection, maintenance, and repair.
Bodywork: Body panel removal, installation, and maintenance.
Procedures Included
Maintenance: Routine maintenance, periodic checks and adjustments, lubrication, fluid changes.
Repair: Step-by-step repair instructions for all major systems, engine rebuilds, transmission overhauls.
Troubleshooting: Advanced troubleshooting guides, diagnostic procedures for common and complex issues.
Diagnostics: Detailed diagnostic procedures to identify faults and problems.
Diagrams Illustrations: Includes step-by-step instructions with diagrams, illustrations, and wiring schematics for all repair and maintenance procedures.
Technical Depth
Depth: Comprehensive, covering everything from basic checks and fluid changes to full engine and transmission rebuilds. Includes detailed specifications and diagrams essential for professional-level repair.
Manual Specifications
File Format
Format: PDF
Compatibility: All versions of Windows and Mac
Requirements: Adobe PDF Reader
Download Speed: Advertised as 'Speed Download'.
Print Quality
Printability: Yes, all pages are printable.
Clarity: Designed for clear viewing and printing of individual pages to avoid damage in a workshop environment.
Binding Type
Binding: N/A (Digital PDF format)
Paper Type
Paper Type: N/A (Digital PDF format)
Engine Specifications
Primary Engine
Type: 2-stroke, single-cylinder (for both 125 and 200 variants)
Displacement
125Cc Variant: Approximately 125cc (Specific bore/stroke for the 125cc models).
200Cc Variant: Approximately 200cc (Specific bore/stroke for the 200cc models).
Performance
Horsepower Torque: Specific figures are detailed within the manual (typical for this era, performance-oriented motocross/off-road engines).
Fuel System
Carburetion: Likely Keihin or Mikuni carburetors (Specific models and jetting detailed in the manual).
Fuel Type: Unleaded gasoline with appropriate octane rating (specified in manual).
Cooling System
Type: Liquid-cooled (Water-cooled via radiator and coolant).
Lubrication
Type: Pre-mix fuel/oil or oil injection system (details specific to model variants will be in manual).
Transmission
Standard
Type: 6-speed manual transmission.
Optional
Options: N/A (Typically a single transmission option for specific models).
Features
Clutch: Hydraulic clutch actuation (common for KTMs of this era).
Gear Ratios: Specific gear ratios for each gear are provided in the manual.
Fluid Requirements
Transmission Oil: Specific type and capacity (e.g., SAE 10W/50, API SG or higher) detailed in manual.
Dimensions
Exterior
Overall Length: Varies by specific model (SX vs. MXC), but detailed in the manual.
Wheelbase: Varies by specific model, detailed in the manual.
Weights
Dry Weight: KTM 125 SX typically around 90-95 kg (200-210 lbs), 200 models slightly more. Exact figures in manual.
Tires
Front Tire Size: Commonly 80/100-21 (details specific to SX/SXS/MXC variants in manual).
Rear Tire Size: Commonly 100/90-19 or 110/90-19 (details specific to SX/SXS/MXC variants in manual).
Wheels
Wheel Type: Spoked wheels with aluminum rims.
Safety Features
Ratings
Crash Test Results: N/A (Motocross/off-road motorcycles are not subject to standard automotive crash testing). Safety is focused on rider protection and vehicle dynamics.
Active Features
Braking System: Hydraulic disc brakes front and rear. Specific caliper and rotor sizes detailed in manual.
Passive Features
Frame Construction: Chromoly steel perimeter frame (known for strength and rigidity).
Technology Features
Infotainment
Features: N/A (These are performance-oriented off-road motorcycles with minimal electronic amenities).
Driver Assistance
Features: N/A (No driver assistance features on these models).
Engine Management
Ignition System: CDI (Capacitor Discharge Ignition) or similar electronic ignition system. Tuning and troubleshooting covered.
Power Valve: Details on the operation, adjustment, and maintenance of the mechanical power valve system.
Maintenance
Service Intervals
Oil Change Frequency: Details for transmission oil and potentially 2-stroke oil levels (if applicable) provided for periodic checks.
Air Filter Cleaning: Recommended intervals and procedures for cleaning/replacing the air filter.
Spark Plug Replacement: Recommended replacement intervals and specific spark plug part numbers.
Chain Tension Adjustment: Regular checks and adjustments are crucial for drivetrain longevity.
Fluid Specifications
Coolant Type: Specific coolant mixture ratio and type (e.g., ethylene glycol-based antifreeze with water).
Brake Fluid: DOT 4 brake fluid (typical for hydraulic systems of this era).
Known Issues
Common Wear Items: Clutch plates, wheel bearings, steering head bearings, fork seals, piston rings, and exhaust packing are common wear items addressed in maintenance schedules and repair procedures.
Specific Problems: The manual will detail troubleshooting for common issues like carburetor performance, ignition problems, and power valve operation.
Vehicle History
Brand Heritage
Ktm Legacy: KTM has a long-standing history in off-road motorsports, particularly motocross and enduro, dating back to the mid-20th century.
Model Evolution
Generations Covered: This manual covers a significant period of evolution for the 125 and 200 SX/SXS/MXC platforms, encompassing design and technological updates from 1999 to 2006.
Production
Manufacturing Location: KTM motorcycles are primarily manufactured in Austria.
Awards & Recognition
Recognitions
Motorsport Success: KTM models of this era have achieved significant success in various off-road racing disciplines, which contributes to their reputation for performance and durability.
Ratings
Industry Reputation: KTM is renowned for producing high-performance, competitive off-road motorcycles known for their advanced engineering and rider ergonomics.
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