Basic Information Identification Make: KTM Model: 125 XC/XC-W, 200 XC/XC-W Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Introduction Market Position Segment: Entry-level to mid-level off-road/enduro motorcycles, popular for their aggressive styling and performance. Competitive Analysis Competitors: Yamaha YZ125/250, Honda CR125R/250R, Suzuki RM125/250, Kawasaki KX125/250. Key Features Vehicle Characteristics: Lightweight, agile, powerful 2-stroke engines (for the era), renowned WP suspension, robust chassis. Manual Value Benefit To Owner: Enables owners to perform maintenance, diagnose issues, and carry out repairs, saving costs and ensuring optimal performance and longevity of their KTM motorcycles. Manual Details Coverage Areas General Coverage: Comprehensive service, repair, and maintenance for KTM 125 XC/XC-W and 200 XC/XC-W models from 1999 to 2006. Page Count Estimated Pages: 300+ Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine: Detailed overhaul, troubleshooting, diagnosis, piston, cylinder, crankshaft, connecting rod, carburetor, ignition system, cooling system. Transmission: Gearbox inspection, repair, clutch service, gear shift mechanism, lubrication. Chassis Suspension: Front fork (WP Suspension) disassembly, assembly, seals, oil levels, rear shock absorber (WP Suspension) service, linkage system maintenance. Brakes: Hydraulic system bleeding, caliper service, pad replacement, master cylinder inspection, disc inspection. Electrical: Wiring diagrams, lighting system, ignition system troubleshooting, battery service, stator, rectifier/regulator. Fuel System: Carburetor tuning and overhaul (likely Keihin or Mikuni), fuel lines, fuel tank maintenance. Bodywork Frame: Frame inspection, plastics removal/installation, seat, handlebars, footpegs. Procedures Included Preventive Maintenance: Scheduled maintenance tasks, fluid changes, filter replacements, lubrication points. Troubleshooting Diagnostics: Systematic fault finding for common and uncommon issues, diagnostic charts, symptom-based troubleshooting. Engine Rebuild: Complete engine disassembly, component inspection, replacement procedures, reassembly torque specifications. Suspension Service: Detailed steps for fork seal replacement, cartridge service, shock absorber rebuild. Carburetor Tuning: Jetting, float adjustment, idle speed settings for optimal performance. Technical Depth Depth: Comprehensive from basic rider maintenance to full engine and chassis overhauls, suitable for home mechanics and professional technicians. Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for easy navigation and information retrieval. Print Quality Quality: Assumed high resolution for clear diagrams and text, suitable for printing. Binding Type Binding: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine 125 Type: 125cc, 2-stroke, liquid-cooled, single-cylinder Bore X Stroke: Approx. 54mm x 54.5mm (typical for this era) Horsepower Est: Approx. 35-40 HP (depending on specific tune and model year) Torque Est: Approx. 20-23 Nm Primary Engine 200 Type: 200cc, 2-stroke, liquid-cooled, single-cylinder Bore X Stroke: Approx. 62.5mm x 65mm (typical for this era) Horsepower Est: Approx. 40-45 HP Torque Est: Approx. 25-28 Nm Fuel System Carburetor Type: Likely Keihin PWK or Mikuni TMX (specific size varies by year/model) Fuel Type: Unleaded gasoline with 2-stroke oil mixture (pre-mix or oil injection depending on specific model variant, but pre-mix is common for these) - check manual for exact ratio. Cooling System Type: Liquid-cooled Transmission Standard Type: 6-speed manual transmission Optional Clutch: Hydraulically operated wet multi-disc clutch Features Gear Ratios: Specific ratios detailed within the manual, crucial for performance tuning. Dimensions Exterior 125 Est Length: Approx. 2100-2200 mm Width: Approx. 800-850 mm Height: Approx. 1200-1250 mm Exterior 200 Est Length: Approx. 2100-2200 mm Width: Approx. 800-850 mm Height: Approx. 1200-1250 mm Weights Dry Weight 125 Est: Approx. 90-95 kg Dry Weight 200 Est: Approx. 95-100 kg Fuel Capacity: Approx. 7-9 liters (check specific model) Safety Features Ratings Safety Standards: Designed for off-road competition and recreational use; not street-legal without modifications and regulatory compliance. Active Features Brakes: Hydraulic disc brakes front and rear for effective stopping power. Passive Features Frame Design: Strong chromoly steel perimeter frame for rigidity and impact resistance. Ergonomics: Designed for rider control and agility in demanding off-road conditions. Technology Features Infotainment Features: N/A - These are performance off-road motorcycles with minimal electronic amenities beyond ignition and lighting. Driver Assistance Features: N/A Connectivity Features: N/A Maintenance Service Intervals Oil Change Engine: Check manual for gearbox oil change intervals (typically every 10-20 hours of riding). Air Filter Cleaning: Recommended every few rides or after dusty conditions. Spark Plug Check: Inspect regularly, replace as needed based on condition. Piston Ring Replacement: Recommended at 40-80 hours of operation, depending on riding style and conditions. Top End Rebuild: Depending on use, a full top-end rebuild (piston, rings, small end bearing) might be needed between 80-150 hours. Fluid Specifications Gearbox Oil: Manual will specify recommended grade, e.g., SAE 10W/40 or 15W/50 motorcycle-specific transmission oil. Capacity approx. 0.7-0.8 liters. Coolant: Ethylene glycol-based coolant (50/50 mix with distilled water) for liquid-cooled engines. Brake Fluid: DOT 4 hydraulic brake fluid. Known Issues Common Wear Items: Clutch plates, piston rings, piston, small end bearing, fork seals, swingarm bearings. Carburetor Icing: Can occur in cold, humid conditions; manual may offer tuning tips. Ignition Coil Failure: Less common, but possible wear item. Vehicle History Brand Heritage Manufacturer...