This manual covers the 125 EGS, 200 EGS, and EXC models, including Six Days editions, produced between 1999 and 2006. These off-road motorcycles are renowned for their high-performance two-stroke engines, capable WP suspension, and robust construction, reflecting a strong legacy in motorsports. Designed for competitive riding and trail use, these models offer a potent combination of power and agility, making them popular choices in the enduro segment. The 125cc variants produce approximately 30-35 HP, while the 200cc models deliver around 38-42 HP, both featuring liquid-cooled, single-cylinder configurations and a 6-speed transmission. This comprehensive service repair manual provides detailed guidance for owners, mechanics, and technicians. It covers all essential aspects of maintenance, diagnostics, and repair for both the 125cc and 200cc engine variants, including complete engine overhauls, carburetor service, and tuning. The manual also details procedures for the chassis, suspension, brakes, fuel, cooling, exhaust, and electrical systems, along with specific instructions for the Six Days models. With in-depth troubleshooting guides and technical specifications, this manual is an indispensable resource for ensuring the optimal performance and longevity of your motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 125 EGS, 200 EGS, EXC, Six Days Engine Variant: 125cc, 200cc Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: Refer to specific model year within manual 👋 Introduction Market Position Segment: Off-road/Enduro motorcycles, popular for competitive riding and trail use. Competitive Analysis Competitors 1999 2006: Yamaha YZ125, YZ250, Honda CR125R, CR250R, Suzuki RM125, RM250, Kawasaki KX125, KX250, Husqvarna WR125/250. Key Features Ktm Legacy: KTM's reputation for high-performance, durable off-road motorcycles. Model Strengths: Strong engines, capable WP suspension, competitive pricing for performance. 📋 Manual Details Coverage Areas Engine Coverage: Complete engine overhaul, diagnostics, tuning, and repair for 125cc and 200cc engines. Chassis Coverage: Suspension, brakes, wheels, fuel system, cooling system, exhaust system, electrical system, frame, and bodywork. Special Editions Covered: KTM Six Days models for applicable years. Page Count Estimated Pages: High (typical for comprehensive service manuals, exact number not specified but expected to be substantial) Manual Type Type: Service Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Cylinder, piston, crankshaft, connecting rod, balancing shaft, camshaft (if applicable), valve train, timing, lubrication system. Fuel System: Carburetor (Mikuni VM/TM series typical), fuel pump, fuel lines, fuel tank, petcock operation and service. Ignition System: CDI unit, ignition coil, spark plug, stator, rotor, wiring diagrams. Cooling System: Radiator, hoses, thermostat, water pump, coolant specifications, bleeding procedures. Exhaust System: Exhaust pipe, silencer, mounting, repacking procedures for silencer. Transmission And Clutch: Gearbox operation, clutch assembly (perch, cable, plates, springs), shift mechanism, lubrication. Chassis And Suspension: Front fork (WP USD typical), rear shock absorber (WP PDS typical), linkages, bearings, steering head bearings. Brakes: Hydraulic brake system (front and rear), calipers, master cylinders, brake lines, brake pads, rotor specifications, fluid types. Electrical System: Wiring diagrams, lighting, battery, charging system (stator, regulator/rectifier), fuses, switches, horn, indicators. Wheels And Tires: Rim specifications, spoke tensioning, wheel bearings, tire size recommendations, inflation pressures. Procedures Included Routine Maintenance: Oil change intervals and specifications, filter replacement, spark plug inspection, chain adjustment and lubrication, air filter cleaning/replacement. Engine Rebuild: Complete engine disassembly, inspection, measurement of wear limits, reassembly procedures, torque specifications. Carburetor Service: Disassembly, cleaning, jetting specifications, float height adjustment, idle speed setting. Suspension Service: Fork oil change and level setting, fork seal replacement, rear shock service, linkage bearing maintenance. Brake System Service: Brake fluid flush and replacement, caliper piston service, pad replacement, bleeding procedures. Electrical Troubleshooting: Diagnostic procedures for common electrical faults, component testing, wiring harness repair. Troubleshooting Guides: Step-by-step diagnosis for starting issues, performance problems, cooling system faults, and electrical gremlins. Technical Depth Depth: Comprehensive from basic maintenance to complete engine and chassis overhauls. Diagnostic Capabilities: Detailed diagnostic procedures and specifications for identifying and resolving mechanical and electrical issues. Special Tools: Lists recommended special tools for specific repair procedures. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable, facilitating quick information retrieval. Print Quality: Assumed to be printable for workshop use, resolution dependent on original scan/creation. Binding Type Binding: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type 125: 2-stroke, single-cylinder, liquid-cooled Bore Stroke 125: Approx. 54mm x 54.5mm (check manual for exact spec) Displacement 125: 124.8 cc Type 200: 2-stroke, single-cylinder, liquid-cooled Bore Stroke 200: Approx. 64mm x 62.2mm (check manual for exact spec) Displacement 200: 193.2 cc Performance Horsepower 125: Approx. 30-35 HP (varies by year and tuning) Horsepower 200: Approx. 38-42 HP (varies by year and tuning) Fuel System Carburetor Type: Mikuni VM series (e.g., VM28/2 for 125, VM30/1 for 200 typical) Fuel Type: Premium Unleaded Gasoline (91 octane or higher recommended) 2 Stroke Oil Mix: Pre-mix (manual will specify ratio, typically 1:40 or 1:50 for Motorex or similar quality oil) 🔧 Transmission...