🏷️ Basic Information Identification Make: KTM Model: 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC Model Years Covered: 1999, 2000, 2001, 2002, 2003 Product Type: Repair Service Manual 👋 Introduction Market Position Segment: Performance Off-Road Motorcycles (Motocross and Enduro) Brand Focus: KTM, known for its 'Ready to Race' philosophy and strong off-road heritage. Competitive Analysis Key Competitors: Yamaha YZ125, Honda CR125R, Suzuki RM125, Kawasaki KX125, Husqvarna WR125. Key Features Vehicle Focus: High-performance, lightweight, agile off-road machines designed for competitive use. Manual Value Proposition: Provides essential technical data and procedures for owners and mechanics to maintain and repair these specialized off-road motorcycles. 📋 Manual Details Coverage Areas Primary Coverage: Repair, Maintenance, Troubleshooting, Specifications Model Specific Coverage: KTM 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, 200 EXC Page Count Estimated Page Count: Variable (PDFs can vary, but comprehensive service manuals for this era typically exceed 200 pages) Manual Type Type: Service/Repair Manual Language Language: English (standard for most imported service manuals of this era) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed disassembly, assembly, inspection, and repair of the 125cc and 200cc two-stroke engines, including top-end, bottom-end, lubrication, cooling, and fuel/ignition systems. Transmission: Service and repair of the gearbox, clutch assembly, shifting mechanisms, and associated components. Suspension: Front fork (WP Suspension) and rear shock absorber (WP Suspension) service, including seal replacement, oil changes, and tuning adjustments. Cover both standard and potentially adjustable models. Brakes: Front and rear brake system service, including hydraulic caliper overhaul, master cylinder service, brake pad replacement, fluid bleeding, and disc inspection. Electrical System: Wiring diagrams, component testing (ignition, lighting, charging system), troubleshooting of electrical faults, and component identification. Fuel System: Carburetor disassembly, cleaning, adjustment, and troubleshooting (likely Keihin or Mikuni depending on specific model variant). Fuel tank and petcock service. Cooling System: Radiator maintenance, coolant replacement, hose inspection, and thermostat (if applicable) service. Exhaust System: Inspection and maintenance of the expansion chamber and silencer. Frame And Bodywork: Inspection, maintenance, and repair of the frame, subframe, plastics, seat, and handlebars. Procedures Included Routine Maintenance: Oil changes, filter replacements, spark plug service, chain adjustment, tire pressure checks, and general inspection points. Engine Rebuild: Complete engine disassembly and reassembly, piston and cylinder replacement, crankshaft bearing service, seal replacement. Troubleshooting Guides: Diagnostic procedures for common performance issues, starting problems, and system failures. Torque Specifications: Detailed torque values for all critical fasteners throughout the vehicle. Special Tools: Identification and usage of specialized tools required for specific repair procedures. Technical Depth Depth Level: Comprehensive, covering from basic owner maintenance to complex engine and chassis overhauls. Diagnostic Capability: Advanced diagnostic information for identifying and resolving mechanical and electrical faults. Repair Procedures: Step-by-step instructions for component removal, repair, and installation. 📊 Manual Specifications File Format File Type: PDF Searchability: Generally searchable text within PDF format, allowing for quick information retrieval. Print Quality Quality Assessment: Typically good to excellent for digital service manuals, with clear diagrams and text. Binding Type Binding Format: N/A (Digital Download) Paper Type Paper Format: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-Stroke, Single Cylinder Displacement 125: Approximately 124-125cc Displacement 200: Approximately 193-200cc Bore X Stroke 125: Varies slightly by year and model, e.g., 54 x 54.5 mm (typical for 125cc) Bore X Stroke 200: Varies slightly by year and model, e.g., 62.5 x 65 mm (typical for 200cc) Cooling System: Liquid-Cooled Ignition System: Digital CDI (Capacitor Discharge Ignition) Carburetor Type: Keihin PWK (e.g., 36mm) or Mikuni TMX (depending on specific model and market) Power Delivery: Aggressive, 'on-the-pipe' powerband characteristic of high-performance two-strokes. Performance Horsepower 125: Approx. 35-38 HP (stock) Horsepower 200: Approx. 40-43 HP (stock) Fuel System Fuel Type: Unleaded gasoline with two-stroke oil premix (typically 50:1 ratio, check manual for specifics). Fuel Capacity: Typically 7-9 liters (approx. 1.8-2.4 US gallons) 🔧 Transmission Standard Type: 6-Speed Manual Sequential Clutch Type: Wet Multi-Plate Clutch Features Gear Ratios: Specific gear ratios are detailed in the manual, optimized for motocross/enduro performance. Final Drive: Chain Drive Transmission Oil Type: Specific gear oil grade (e.g., SAE 80 or SAE 10W/40 for wet clutches, check manual for exact specification). 📐 Dimensions Exterior Frame Type: Chromoly Steel Trellis Frame Front Suspension: WP Upside-Down (USD) Conventional Fork (e.g., 43mm or 48mm diameter depending on model year/variant) Rear Suspension: WP PDS (Progressive Damping System) Monoshock with Linkage Front Brake: Hydraulic Disc (e.g., 260mm) Rear Brake: Hydraulic Disc (e.g., 220mm) Front Tire Size: 80/100-21 (typical for off-road) Rear Tire Size: 100/90-18 or 110/90-18 (typical for off-road) Weights Dry Weight 125: Approx. 90-95 kg (198-210 lbs) Dry Weight 200: Approx. 95-100 kg (210-220 lbs) 🛡️ Safety Features Ratings Safety Ratings: N/A (Off-road motorcycles are not subject to DOT or NHTSA safety ratings in the same way as street vehicles). Active Features Active Safety: Powerful brakes, agile handling, good rider ergonomics...