This manual covers the 125 XC, 200 XC, and XC-W models produced between 1999 and 2006. The brand is renowned for its high-performance off-road motorcycles, emphasizing racing heritage and innovative engineering. These models are designed for off-road competition and enduro riding, known for their lightweight chassis, powerful two-stroke engines, agile handling, and robust suspension systems. They compete in a segment valued for agility and power-to-weight ratio, reflecting the brand's commitment to specialized, high-capability machines. This comprehensive English-language service repair manual provides detailed guidance for engine service and repair, alongside essential maintenance, troubleshooting, and technical data. It covers critical systems including the engine mechanical and electrical components, transmission, clutch, and fuel system, detailing procedures from routine maintenance like oil changes and filter replacements to complete engine overhauls and carburetor tuning. The manual is intended for professional motorcycle technicians and experienced DIY enthusiasts, offering the in-depth information required to maintain and repair these specialized off-road motorcycles effectively. 🏷️ Basic Information Identification Make: KTM Model: 125 XC / 200 XC / XC-W Model Variant: Engine Service Repair Manual Model Year: 1999-2006 Codes Engine Codes: Not explicitly specified in product information, but common for this era would include LC2, LC4 variants for engine architecture. 👋 Introduction Market Position Segment: Off-road Competition (XC - Cross Country), Enduro (XC-W - Cross Country Enduro) Competitive Analysis Competitors: During this era, KTM competed with brands like Yamaha (YZ series), Honda (CRF series), Suzuki (RM series), Kawasaki (KX series), and Husqvarna in the off-road motorcycle segment. Specific engine platforms like the 125cc and 200cc two-stroke engines were popular for their agility and power-to-weight ratio in competitive racing and trail riding. Key Features Brand Focus: KTM is renowned for its high-performance off-road motorcycles, emphasizing racing heritage and innovative engineering. This manual reflects the detailed technical information required to maintain and repair these specialized machines. 📋 Manual Details Coverage Areas Primary Coverage: Engine Service and Repair Secondary Coverage: Maintenance, Troubleshooting, Overhaul, Technical Data Page Count Estimated Page Count: Likely 200-400 pages, typical for comprehensive service manuals of this era covering specific engine platforms. Manual Type Type: Service Repair Manual Intended User: Professional motorcycle technicians and experienced DIY enthusiasts. Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Cylinder Head, Cylinder, Piston, Crankshaft, Connecting Rod, Crankcase, Lubrication System, Cooling System (if applicable to specific engine variant) Engine Electrical: Ignition System, Carburetor/Fuel Injection System (if applicable), Starting System (kick starter specific, potentially electric starter components if fitted to certain models/years) Transmission: Gearbox Internals, Clutch Assembly, Shift Mechanism Fuel System: Carburetor (specific models and tuning), Fuel Lines, Fuel Filter Ignition System: CDI ignition, stator, coil, spark plug specifications, and troubleshooting. Cooling System: Radiator, hoses, water pump, thermostat (if applicable), and bleeding procedures. Procedures Included Maintenance: Oil Change, Filter Replacement, Spark Plug Service, Valve Clearance Adjustment, Air Filter Cleaning/Replacement Repair: Engine Rebuild (Top-end and Bottom-end), Clutch Overhaul, Transmission Repair, Carburetor Rebuild and Adjustment Troubleshooting: Diagnostic Flowcharts, Common Issues and Solutions, Symptom-based troubleshooting Technical Data: Torque Specifications, Clearances, Tolerances, Special Tool Requirements Special Tools: Identification and usage of specialized KTM tools required for specific tasks like engine assembly, suspension service, or flywheel removal. Technical Depth Depth: Comprehensive, covering routine maintenance to full engine disassembly, rebuild, and calibration. Suitable for experienced mechanics and dedicated DIY enthusiasts. 📊 Manual Specifications File Format Quality: Digital PDF, typically with searchable text and clear, high-resolution diagrams. Print quality will depend on the source document. Searchability: PDF format typically offers full text search capabilities, allowing users to quickly locate specific procedures or information. Print Quality Quality: N/A (Digital PDF) Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, Two-stroke (primarily, though some later 4-strokes may exist, this manual focuses on the 2-stroke era for these displacements) Displacement: 125cc and 200cc (specific bore and stroke would vary between models) Cooling System: Liquid-cooled (typical for KTM off-road bikes of this era) Bore Stroke: Specific bore and stroke measurements for 125cc and 200cc variants are detailed in the manual. Compression Ratio: Typically in the range of 12.5:1 to 14.5:1 for performance two-strokes of this era. Manual will provide exact figures for each model. Performance Horsepower Range: Estimated 30-40+ HP depending on exact model, year, and state of tune (specific figures are in the manual) Torque Range: Specific figures vary by model and year, detailed in manual. Fuel System Carburetor Type: Mikuni or Keihin carburetors, typically with specific jetting and setup for optimal performance. Manual will detail specific models and settings. Fuel Grade: High-octane unleaded gasoline mixed with appropriate 2-stroke oil at the specified ratio (e.g., 40:1, 50:1). Manual will specify oil type and ratio. 🔧 Transmission Standard Type: 6-speed constant mesh Optional Type: N/A (typically a single transmission type per model variant) Features Clutch: Hydraulic clutch actuation (common on KTMs), Wet...