This manual covers the 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, and 200 EXC models from the 2001 model year. These high-performance off-road motorcycles are renowned for their robust engineering and 'Ready to Race' philosophy, reflecting a strong heritage in motorsport. Designed for demanding off-road use, these models offer powerful two-stroke engines and advanced chassis components, making them a popular choice for enthusiasts and competitors alike. This comprehensive service repair manual provides detailed guidance for all aspects of maintenance, troubleshooting, and repair. It includes step-by-step procedures for engine mechanicals, fuel and ignition systems, transmission, suspension, brakes, electrical systems, and chassis components. With extensive coverage of routine maintenance, engine rebuilds, component overhauls, and diagnostic procedures, this manual is an indispensable resource for owners and technicians seeking to maintain the optimal performance and reliability of their off-road motorcycles. 🏷️ Basic Information Identification Make: KTM Model: 125 SX, 200 SX, 125 MXC, 200 MXC, 125 EXC, 200 EXC Model Years Covered: 2001 Codes Chassis Codes: Likely to include specific chassis codes for each model variant (e.g., for 125 EXC, it might be related to the EXC chassis family). Engine Codes: Specific engine codes for 125cc and 200cc two-stroke engines of that era. 👋 Introduction Market Position Segment: High-performance off-road motorcycles (motocross, enduro). Target Audience: Enthusiasts, mechanics, and owners performing their own maintenance and repairs. Competitive Analysis Competitors: Yamaha YZ125, Honda CR125R, Suzuki RM125, Kawasaki KX125 (for 125cc models); similar displacement two-strokes from other manufacturers for 200cc models. Key Features Brand Focus: KTM's reputation for 'Ready to Race' performance and robust engineering. Manual Value Proposition: Empowers owners to maintain and repair their KTMs, potentially saving on labor costs and ensuring optimal performance. 📋 Manual Details Coverage Areas Primary Coverage: Comprehensive service, repair, and maintenance procedures for the specified KTM models. Secondary Coverage: Troubleshooting, diagnostics, rebuilding, and refurbishment. Page Count Estimated Page Count: Likely 300-500+ pages, typical for a full service manual. Manual Type Type: Full Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine overhaul, piston, rings, cylinder, crankshaft, connecting rod, bearings, seals, gaskets, lubrication system, cooling system (if applicable). Fuel System: Carburetor(s) (e.g., Keihin PWK), fuel lines, fuel petcock, fuel filter, jetting specifications. Ignition System: Spark plug, ignition coil, CDI unit, stator, wiring diagrams. Exhaust System: Expansion chamber, silencer, gaskets, mounting hardware. Transmission Drivetrain: Gearbox, clutch operation, shift mechanism, chain and sprockets, chain adjustment and lubrication. Suspension Front: Front fork overhaul, oil seals, dust seals, springs, damping adjustments, fork leg maintenance. Suspension Rear: Rear shock absorber service, linkage bearings, swingarm maintenance, preload and damping adjustments. Brakes Front: Brake caliper service, master cylinder overhaul, brake pads, brake fluid, bleeding procedure, rotor inspection. Brakes Rear: Rear brake caliper service, master cylinder overhaul, brake pads, brake fluid, bleeding procedure, rotor inspection. Wheels Tires: Wheel bearing inspection and replacement, tire pressure recommendations, rim maintenance, spoke tension. Electrical System: Wiring diagrams, lighting (headlight, taillight, brake light), battery maintenance, fuse replacement, switchgear. Frame Chassis: Frame inspection, steering head bearings, footpegs, controls, subframe maintenance. Bodywork Plastics: Fender removal/installation, seat maintenance, fuel tank removal/installation, graphics. Procedures Included Routine Maintenance: Oil changes, filter cleaning/replacement, chain lubrication, spark plug checks, air filter service, general inspection. Engine Rebuild: Complete engine teardown, inspection, and reassembly of all internal components. Suspension Overhaul: Detailed steps for servicing front forks and rear shock absorbers, including fluid changes and seal replacement. Brake Service: Pad replacement, caliper cleaning, piston service, brake fluid flush and bleed. Carburetor Rebuild Tuning: Disassembly, cleaning, reassembly of carburetors, jetting adjustments, idle speed setting. Troubleshooting: Diagnostic procedures for common performance issues, starting problems, electrical faults. Torque Specifications: Precise torque values for all critical fasteners. Wiring Diagrams: Detailed electrical schematics for all systems. Assembly Disassembly: Step-by-step instructions for removing and installing major components. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to full engine and chassis rebuilds. Diagnostic Capability: Detailed troubleshooting guides and symptom-based diagnostics. Component Rebuild: In-depth procedures for rebuilding major components like the engine, transmission, and suspension. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if properly created. Print Quality Quality: Assumed to be high-resolution for clear diagrams and text. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Quality: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: Two-stroke, single-cylinder Bore Stroke 125: Typical for 125cc two-strokes of the era (e.g., approx. 54mm bore x 54.5mm stroke, but requires manual verification). Bore Stroke 200: Typical for 200cc two-strokes of the era (e.g., approx. 64mm bore x 60mm stroke, but requires manual verification). Cooling: Liquid-cooled Reed Valve System: Likely uses a reed valve intake system for improved low-end power. Performance Horsepower 125: Estimated 30-35 HP (subject to model and specific tuning). Horsepower 200: Estimated 35-40 HP (subject to model and specific tuning). Torque: Specific torque figures would be in...