Basic Information Identification Make: KTM Model: 125 / 200 Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Internal Product Code: KTM125-200-99-06-SM Introduction Market Position Segment: Entry-level sport motorcycles, dual-sport/enduro motorcycles (depending on specific variant) Target Audience: New riders, commuting, recreational off-road use Competitive Analysis Key Competitors: Yamaha YZ125/WR125, Honda CR125/XR125, Suzuki RM125/DR125, Kawasaki KX125/KLX125 Key Features Brand Philosophy: KTM's 'Ready to Race' ethos, focused on performance and off-road capability Model Strengths: Lightweight chassis, potent (for its class) two-stroke engines, agile handling, robust suspension Manual Details Coverage Areas Primary Coverage: Service, Repair, Workshop Page Count Estimated Page Count: 400-600 Manual Type Manual Type: Workshop Service Manual Language Language: English Format Format: PDF Download Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, troubleshooting, cylinder head, piston, crankshaft, connecting rod, valves, timing, lubrication system, cooling system Fuel System: Carburetor (Mikuni VM series or similar), fuel pump, fuel lines, fuel tank, fuel filter Ignition System: CDI, ignition coil, spark plug, stator, rotor, troubleshooting Exhaust System: Exhaust pipe, muffler, gasket replacement Transmission Drivetrain: Gearbox, clutch (wet multi-plate), shift mechanism, chain drive, sprockets, lubrication Chassis Frame: Frame construction, subframe, swingarm, bearings, bushings Suspension Front: Upside-down telescopic forks (e.g., WP Suspension), fork seals, oil change, internal components, adjustment Suspension Rear: Monoshock absorber (e.g., WP Suspension), linkage system, rear shock adjustment, rebuild Brakes Front: Hydraulic disc brake, brake caliper, master cylinder, brake pads, brake discs, fluid flush and bleed, troubleshooting Brakes Rear: Hydraulic disc brake, brake caliper, master cylinder, brake pads, brake discs, fluid flush and bleed, troubleshooting Wheels Tires: Wheel bearing replacement, spoke tensioning, tire mounting and balancing, recommended tire pressures Electrical System: Wiring diagrams, battery, starter motor, lighting (headlight, taillight, indicators), horn, fuses, relays, troubleshooting Controls Cables: Throttle cable, clutch cable, brake cables, lever adjustment, replacement Bodywork Fairings: Panel removal and installation, graphics, seat, fuel tank cover Procedures Included Routine Maintenance: Oil and filter changes, spark plug inspection/replacement, chain adjustment, air filter cleaning/replacement, brake inspection, tire pressure checks Major Repairs: Engine rebuild (top-end and bottom-end), transmission overhaul, clutch replacement, fork seal replacement, shock absorber rebuild Troubleshooting: Diagnostic procedures for common problems, electrical faults, engine running issues, starting problems Component Disassembly Assembly: Step-by-step instructions for removing, inspecting, servicing, and reinstalling major components Tightening Torques: Specific torque values for critical fasteners Special Tools: Identification and usage of specialized tools required for certain procedures Technical Depth Diagnostic Capabilities: In-depth troubleshooting guides, symptom-based diagnostics Rebuild Instructions: Comprehensive guides for complete engine, transmission, and suspension rebuilds Electrical Schematics: Detailed wiring diagrams for all electrical systems Component Specifications: Detailed specifications for all serviceable parts, including clearances, tolerances, and wear limits Manual Specifications File Format File Type: PDF Searchability: Text-searchable PDF Print Quality Print Readability: High-resolution, printable pages Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Engine Specifications Primary Engine Engine Type: Single-cylinder, 2-stroke Displacement 125: 125cc Displacement 200: 200cc (approximate) Bore Stroke 125: 54mm x 54.5mm (typical, may vary) Bore Stroke 200: 62.5mm x 65mm (typical, may vary) Cooling System: Liquid-cooled Power Valve: Yes (KTM's PowerJet/APTC system likely) Performance Horsepower 125: Approx. 30-35 HP (stock, may vary by region/emission standards) Horsepower 200: Approx. 35-40 HP (stock, may vary) Torque: Varies by model, approximately 20-25 Nm for 125, 25-30 Nm for 200 Fuel System Carburetor Size: 36mm Mikuni VM (typical for 125/200 models) Fuel Type: Unleaded gasoline (95 octane recommended), 2-stroke oil mixture (pre-mix or oil injection depending on specific model variant) Transmission Standard Transmission Type: 6-speed constant mesh Optional Transmission Options: N/A (Manual transmission standard) Features Clutch Type: Wet multi-plate clutch Final Drive: Chain drive Dimensions Exterior Wheelbase Approx: 1450mm - 1480mm (varies by specific model) Seat Height Approx: 920mm - 950mm (varies by specific model) Weights Dry Weight Approx: 95-110 kg (varies significantly by model and trim) Safety Features Ratings Safety Ratings: N/A (Motorcycles typically do not have formal crash test ratings like cars) Active Features Braking System: Disc brakes front and rear, hydraulic actuation Tire Considerations: Proper inflation and tread depth are critical for grip and stability Passive Features Lighting: Headlight, taillight, brake light, turn signals Technology Features Infotainment Infotainment Systems: N/A (Basic instrumentation only - speedometer, tachometer, odometer, engine hour meter, indicator lights) Driver Assistance Rider Aids: N/A (No electronic rider aids like ABS or traction control on these models) Connectivity Connectivity Features: N/A Maintenance Service Intervals Oil Change Interval: Every 10-15 hours of riding or annually. Check manual for specific mileage/time. Air Filter Cleaning: Every 5-10 hours of riding, or more frequently in dusty conditions. Spark Plug Inspection: Every 15-20 hours of riding. Chain Lubrication Adjustment: Every 500-1000 km or as needed based on slack. Fluid Specifications Engine Oil Type 2Stroke: High-quality synthetic 2-stroke oil, premixed or for oil injection system (specific formulation per manual). Cooling System Coolant: Ethylene glycol based coolant with anti-corrosion additives (e.g., Motorex...