This manual covers 125, 144, 150, and 200 models produced between 1999 and 2010. These Austrian-engineered machines are recognized for their performance-oriented design, often derived from competitive off-road platforms. Featuring potent two-stroke, liquid-cooled single-cylinder engines and robust chassis components, these motorcycles offer an engaging riding experience. Common engine variants include those utilizing Mikuni or Keihin carburetors, and they are equipped with 6-speed constant mesh transmissions and wet multi-plate clutches. Known for their agility and power, models from this period are celebrated in their respective classes for their competitive edge. This comprehensive service repair workshop manual provides detailed guidance for owners, independent repair shops, and technicians. It covers a wide array of systems, including engine overhaul, transmission repair, drivetrain maintenance, fuel and electrical systems, suspension, brakes, and steering. The manual offers step-by-step instructions for routine maintenance, component rebuilds, and troubleshooting common issues, alongside essential specifications and wiring diagrams. Its vehicle-specific content ensures accuracy, empowering users to maintain and repair their motorcycles effectively, thus facilitating significant cost savings on service and repairs. 🏷️ Basic Information Identification Make: KTM Model: 125, 144, 150, 200 Production Years: 1999-2010 Codes Engine Codes: Varies by specific model (e.g., LC2, SX, EXC variants) 👋 Introduction Market Position Target Audience: KTM owners, independent repair shops, and technicians seeking detailed repair and maintenance information. Competitive Analysis Value Proposition: Provides dealership-level repair information, enabling significant cost savings on maintenance and repairs. Key Features Content Style: Step-by-step instructions, diagrams, illustrations, wiring schematics, specifications. Accuracy: Vehicle-specific, not generic, ensuring accurate repair procedures. 📋 Manual Details Coverage Areas Covered Models: KTM 125, 144, 150, 200 Covered Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Page Count: Varies significantly based on specific model year and engine size, but comprehensive manuals typically exceed 400 pages. Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete overhaul, top-end and bottom-end rebuilds, carburetor tuning, ignition system, cooling system. Transmission: Gearbox inspection, repair, clutch service, shift mechanism. Drive Train: Drive chain maintenance, sprocket inspection and replacement, rear hub and wheel assembly. Fuel System: Fuel tank, fuel lines, carburetor (Mikuni, Keihin models common), fuel pump (if applicable). Electrical System: Wiring diagrams, lighting system, ignition coil, stator, CDI unit, battery maintenance, starter system (if electric start equipped). Suspension: Front fork service (WP Suspension common), rear shock absorber service and adjustments, linkage maintenance. Brakes: Hydraulic brake system service (front and rear calipers, master cylinders), brake fluid replacement, pad inspection and replacement, rotor inspection. Steering System: Steering head bearing inspection and adjustment, handlebar and control assembly. Bodywork: Fairing removal and installation, seat, fenders, plastics. Intake Exhaust: Airbox, air filter, exhaust pipe, silencer. Procedures Included Routine Maintenance: Oil changes, air filter cleaning/replacement, chain lubrication and adjustment, spark plug checks, coolant checks. Troubleshooting: Diagnostic procedures for common starting issues, engine performance problems, electrical faults. Repair Procedures: Step-by-step instructions for component disassembly, cleaning, inspection, and reassembly. Component Rebuilds: Engine top-end (piston, rings, cylinder, head), gearbox rebuilds, carburetor overhauls. Wiring Diagrams: Detailed electrical schematics for all systems. Specifications Data: Torque values, clearances, fluid capacities, performance data. Technical Depth Depth: Comprehensive, from basic maintenance to full engine and chassis rebuilds, suitable for professional mechanics and experienced DIYers. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: High quality, printable pages Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) Compatibility Operating Systems: Windows and Mac compatible Requirements Software Requirements: Adobe PDF Reader ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled single-cylinder Performance 125 Approx Hp: ~35-40 HP (varies by year and specific model variant) 150 Approx Hp: ~40-45 HP (varies by year and specific model variant) 200 Approx Hp: ~45-50 HP (varies by year and specific model variant) Fuel System Carburetor Models: Mikuni VM series, Keihin PWK series common depending on year and model. Fuel Type: Unleaded gasoline with 2-stroke oil mixture (premix or oil injection systems vary). 🔧 Transmission Standard Gearbox Type: 6-speed constant mesh Features Clutch Type: Wet multi-plate clutch 📐 Dimensions Weights Dry Weight Approx: 85-105 kg (highly dependent on specific model and year) Wet Weight Approx: 95-115 kg (highly dependent on specific model and year) 🛡️ Safety Features Active Features Braking System: Hydraulic disc brakes front and rear (Brembo calipers common on many models). 💡 Technology Features Infotainment Features: Basic instrumentation (speedometer, tachometer, odometer, engine hour meter) common for this era and segment. Driver Assistance Features: N/A (Focus on rider input and mechanical feedback) 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual for specific recommendations based on usage (e.g., every 10-20 hours of off-road riding, or as per kilometers for street use). Top End Rebuild Interval: Highly variable based on riding style and maintenance. Typically 50-150 hours for performance engines. Fluid Specifications Engine Oil Type: 2-stroke...