This manual covers the 125 EXC, SX, MXC, EGS, and LC2 models, as well as the 200 EXC, SX, MXC, and EGS variants produced between 1999 and 2003. These off-road motorcycles are powered by robust single-cylinder, two-stroke engines, known for their strong power-to-weight ratios and competitive performance in their respective classes. The legacy in off-road racing is evident in the design and engineering of these agile and durable machines, which are equipped with liquid-cooled engines, 6-speed transmissions, and hydraulic disc brakes. This comprehensive English-language service manual provides detailed guidance for owners, independent repair shops, and experienced DIY mechanics. It covers a wide range of essential maintenance procedures, from routine checks and component replacements to complete engine rebuilds and troubleshooting. The manual includes in-depth information on engine mechanicals, cooling and lubrication systems, ignition and fuel systems, exhaust systems, torque specifications, and specialized tools. Its detail level is comparable to factory service manuals, ensuring professional-level repair and maintenance capabilities. 🏷️ Basic Information Identification Make: KTM Model: 125 EXC / SX / MXC / EGS / LC2; 200 EXC / SX / MXC / EGS Year: 1999-2003 Engine Type: Two-Stroke Single-Cylinder Codes Product Id: N/A (Manual Download) 👋 Introduction Market Position Target Audience: KTM owners, independent repair shops, experienced DIY mechanics Value Proposition: Provides professional-level repair and maintenance guidance, enabling owners to service their own bikes effectively. Competitive Analysis Comparison To Oem: Comparable in detail and accuracy to official KTM factory service manuals used by authorized dealers. Key Features Detail Level: Highly detailed with step-by-step instructions and exploded diagrams. Diagnostic Focus: Emphasizes troubleshooting to identify and resolve engine performance issues. 📋 Manual Details Coverage Areas Models Covered: KTM 125 (EXC, SX, MXC, EGS, LC2) and KTM 200 (EXC, SX, MXC, EGS) variants Years Covered: 1999, 2000, 2001, 2002, 2003 Page Count Page Count: 158 Manual Type Manual Type: Engine Repair Manual / Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, inspection, repair, and reassembly Cooling System: Radiator, hoses, water pump, thermostat (if applicable) Lubrication System: Oil pump, oil passages, mixture lubrication system (Premix) Ignition System: Ignition coil, CDI unit, spark plug, timing specifications Fuel System: Carburetor (model and jetting details), fuel delivery, fuel lines Exhaust System: Exhaust pipe, silencer, internal components, sealing Procedures Included Routine Maintenance: Spark plug replacement, air filter cleaning/replacement, carburetor adjustment, coolant checks, chain maintenance Troubleshooting: Diagnostic charts, common problems and their solutions Engine Rebuild: Piston and ring replacement, cylinder honing/replating, crankshaft bearing service, clutch service, gearbox overhaul Component Replacement: Water pump, reed valves, kick starter mechanism, clutch plates and springs Torque Specifications: Detailed torque values for all critical fasteners Technical Depth Depth Level: Comprehensive, from basic checks to full engine rebuilds and diagnostics Diagnostic Capabilities: In-depth diagnostic procedures for engine performance issues Special Tools: Lists and descriptions of specialized tools required for specific procedures 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if a well-scanned original Print Quality Quality Level: Variable (dependent on original source scan, but generally high for service manuals) Binding Type Binding Method: N/A (Digital Download) Paper Type Paper Material: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Configuration: Single-cylinder, two-stroke Bore X Stroke 125: 54.0 mm x 54.5 mm (typical) Bore X Stroke 200: 64.0 mm x 62.0 mm (typical) Displacement 125: 124.8 cc Displacement 200: 199.6 cc Cooling: Liquid-cooled Reed Block: V-Force reed block common on these models Performance Horsepower 125: Approx. 32-35 hp (stock, depending on model variant and tuning) Horsepower 200: Approx. 38-40 hp (stock, depending on model variant and tuning) Torque: Torque figures vary by specific model and tune, but are optimized for off-road performance. Fuel System Carburetor Type: Keihin PWK (common) or Mikuni TM, with specific sizes like 38mm often used. Fuel Mixture: 2-stroke oil premix (typically 50:1 or 60:1, consult manual for specifics). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh sequential manual Optional Clutch Type: Hydraulically operated, multi-plate wet clutch Features Gearbox Design: Robust design optimized for aggressive off-road use. Clutch Maintenance: Includes procedures for clutch plate inspection, replacement, and hydraulic system bleeding. 📐 Dimensions Exterior Body Style: Off-road motorcycle (Enduro/Motocross variants) Weights Dry Weight Approx 125: Approx. 98-105 kg (216-231 lbs) depending on model Dry Weight Approx 200: Approx. 100-107 kg (220-236 lbs) depending on model 🛡️ Safety Features Ratings Safety Certification: N/A for off-road motorcycles in typical automotive safety rating context Active Features Braking System: Hydraulic disc brakes (front and rear) with Brembo components common. Passive Features Frame Construction: Chromoly steel trellis frame 💡 Technology Features Infotainment Instrumentation: Basic analog tachometer and speedometer, trip meter, neutral indicator light. Driver Assistance Electronics: Primary electronic systems relate to the ignition (CDI) and lighting. Connectivity Connection Features: N/A (Not applicable to these models) 🔧 Maintenance Service Intervals Oil Change Frequency: Regularly check and top...