This manual covers the XTC 125 motorcycle, specifically the 4-stroke variant, for production years 2002 through 2007. Known for its robust engineering and reliability, the XTC 125 is a popular choice in the 125cc class, often serving as an entry-level or commuter sport/naked bike. This machine benefits from a heritage in producing quality automotive and motorcycle components, ensuring a dependable riding experience. This comprehensive Factory Service Repair Workshop Manual provides detailed guidance for all aspects of the XTC 125. It encompasses full service and repair procedures, including in-depth maintenance schedules, troubleshooting common issues, and complete overhaul instructions for all major systems such as the engine, fuel, ignition, transmission, brakes, and electrical components. With hundreds of detailed photos and diagrams, this manual is an essential resource for owners and independent repair shops seeking to maintain, diagnose, and repair their vehicle effectively. 🏷️ Basic Information Identification Make: SACHS Model: XTC 125 Model Variant: 40 STROKE Production Years Covered: 2002, 2003, 2004, 2005, 2006, 2007 Category: Motorcycle Engine Type: 4-Stroke 👋 Introduction Market Position Target User: SACHS XTC 125 owners and independent repair shops Value Proposition: Provides professional-level repair and maintenance guidance, saving costs on dealership services Key Features Completeness: Covers all repairs, servicing, and troubleshooting procedures Instruction Style: Step-by-step instructions with detailed visual aids Accessibility: Instant download for immediate use on multiple devices 📋 Manual Details Coverage Areas Primary Coverage: Full Service & Repair Secondary Coverage: Servicing, Troubleshooting Page Count Estimated Page Count: Hundreds Manual Type Type: Factory Service Repair Workshop Manual Language Language: English Format Format: PDF Download Accessibility: Instant Download Compatibility Operating Systems: Windows & MAC Computers Licensing Usage Rights: Unlimited Installations Subscription Model: No Expiry Dates, No Renewal Fees 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, diagnostics, emissions Fuel System: Carburetor settings, fuel pump, fuel lines, tank maintenance Ignition System: Spark plugs, coil packs, CDI unit, timing Cooling System: Radiator, thermostat, coolant flush and fill Exhaust System: Muffler, exhaust pipes, gasket replacement Transmission: Gearbox removal and installation, clutch adjustment and replacement, internal components Drivetrain: Chain adjustment, sprocket replacement Frame And Suspension: Front fork servicing, rear shock absorber replacement, steering head bearing maintenance Brakes: Front and rear brake caliper service, master cylinder overhaul, brake fluid flush, pad and disc replacement Electrical System: Wiring diagrams, battery maintenance, lighting, charging system, starter motor, switches Bodywork And Fittings: Fairing removal and installation, seat, fenders, handlebars Wheels And Tires: Tire changing, wheel bearing inspection and replacement Procedures Included Maintenance: Scheduled maintenance checks, oil changes, filter replacements, lubrication points Troubleshooting: Diagnosis of common problems, fault finding procedures Repair: Step-by-step repair instructions for all major components Rebuilds: Engine and transmission rebuild procedures Adjustments: Carburetor synchronization, chain tension, brake lever free play Diagnostics: Electrical system testing, engine performance analysis Technical Depth Depth: Comprehensive, from basic maintenance to complete overhaul Illustrations: Hundreds of detailed photos & diagrams, exploded views Level Of Detail: Professional mechanic and technician level 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text (standard for professional PDFs) Print Quality Printability: Printable (single page or entire manual) Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Size: 125cc Class Engine Configuration: Single-cylinder, 4-stroke (as indicated by '40 STROKE' and '4-STROKE' in description) Performance Power Output: Specific HP/Torque figures would be detailed within the manual, typically around 10-15 HP for this class Fuel System Carburetor Type: Likely a Mikuni or Keihin carburetor, specifications and jetting detailed in manual Lubrication Oil Type: Specific motorcycle-grade oil (e.g., SAE 10W-40, API SG or higher) would be specified Oil Capacity: Capacity for engine oil would be detailed, likely around 1-1.5 liters 🔧 Transmission Standard Type: Likely a 5-speed or 6-speed constant-mesh gearbox Features Clutch Type: Wet multi-plate clutch Fluid Type Transmission Oil: Specific motorcycle gearbox oil specification would be provided 📐 Dimensions Exterior Wheelbase: Specific wheelbase dimensions would be available in the manual Weights Dry Weight: Typical dry weight for a 125cc sport/naked bike in this era would be around 110-130 kg 🛡️ Safety Features Active Features Braking System: Disc brakes front and rear (typical for this model) Passive Features Lighting: Headlight, taillight, turn signals, brake lights 💡 Technology Features Infotainment Features: Basic analog or digital instrument cluster (speedometer, tachometer, odometer, fuel gauge if equipped) Driver Assistance Features: N/A (No advanced electronic rider aids expected on this model) 🔧 Maintenance Service Intervals Oil Change Interval: Typically every 3,000-5,000 km or annually, specified in manual Chain Adjustment: Regular checks, typically every 1,000 km or as needed based on stretch Spark Plug Replacement: Manufacturer specified intervals, e.g., every 6,000-10,000 km Fluid Specifications Brake Fluid Type: DOT 3 or DOT 4 (standard for most motorcycles of this era) Coolant Type: Ethylene glycol-based antifreeze, specified in manual Known Issues Common Wear Items: Clutch plates, brake pads, chain and sprockets, fork seals, carburetor...