This manual covers the 125 SX, 125 MXC, 125 EXC, 200 SX, 200 MXC, and 200 EXC models produced between 1999 and 2003. These high-performance off-road motorcycles are engineered with a renowned 'Ready to Race' philosophy, offering lightweight, agile designs for competitive motocross and enduro use. Known for their robust construction and potent two-stroke engines, these models represent a significant era of performance and chassis development for the Austrian brand, which boasts a rich heritage in off-road racing. This comprehensive Repair Service Manual provides detailed information essential for the maintenance and repair of your motorcycle. It includes step-by-step procedures for engine disassembly and assembly, transmission and clutch service, suspension maintenance for WP components, brake system overhauls, and electrical system troubleshooting. With coverage of routine maintenance, troubleshooting guides, torque specifications, and necessary special tools, this manual is an indispensable resource for owners and technicians seeking to keep these specialized off-road machines in optimal condition. 🏷️ 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:...