This manual covers a range of off-road motorcycles, including the 125, 144, 150, 200 SX, SXS, MXC, EGS, EXC, EXC Six Days, XC, and XC-W models produced between 1999 and 2010. These bikes, powered by 125cc, 144cc, 150cc, and 200cc two-stroke, liquid-cooled engines, are renowned for their racing heritage and performance in motocross, enduro, and trail riding. Engineering quality is evident in their robust construction and competitive capabilities, making these models a popular choice for enthusiasts and competitors alike. This comprehensive factory service repair workshop manual provides detailed, step-by-step instructions, hundreds of pages of content, and exploded diagrams to assist with all aspects of maintenance and repair. It covers engine service, troubleshooting, general servicing, and in-depth repair procedures for critical systems including the engine internal components, fuel system, ignition system, exhaust, cooling, lubrication, and electrical systems. This English-language manual is designed for owners, DIY mechanics, and professional technicians, offering factory-level documentation to ensure optimal performance and longevity of your motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 125, 144, 150, 200 SX, SXS, MXC, EGS, EXC, EXC Six Days, XC, XC-W Engine Variants: 125cc, 144cc, 150cc, 200cc Production Years: 1999-2010 Codes Product Type: Service Repair Workshop Manual 👋 Introduction Market Position Target Audience: KTM owners, DIY mechanics, professional technicians, enthusiasts Positioning: These models are positioned as competitive and capable off-road machines for motocross, enduro, and trail riding. The manual supports owners who want to maintain or repair them to factory standards. Competitive Analysis Value Proposition: Comprehensive, factory-level documentation for a wide range of KTM off-road models covering a significant production span. Key Features Detail Level: Hundreds of pages with detailed photos, diagrams, and step-by-step instructions. Usability: Cross-platform compatibility (Windows/MAC), printable, lifelong access. 📋 Manual Details Coverage Areas Coverage: Engine Service, Repair, Troubleshooting, Servicing Page Count Pages: Hundreds (detailed) Manual Type Type: Factory Service Repair Workshop Manual Content Type: Professional, step-by-step instructions with detailed photos and exploded diagrams. Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Internal: Cylinder, piston, connecting rod, crankshaft, valve train (if applicable), lubrication system, cooling system (if applicable) Fuel System: Carburetor(s) (jetting, float levels, cleaning, adjustment), fuel lines, fuel pump (if applicable) Ignition System: Spark plug, ignition coil, CDI unit, stator, wiring Exhaust System: Exhaust pipe, muffler, packing, sealing Cooling System: Radiator, hoses, coolant, water pump (if applicable) Lubrication System: Oil pump (if applicable), oil filters, oil passages, pre-mix specifications (if applicable) Electrical System: Wiring diagrams, lighting (if applicable), ignition system components, battery (if electric start models exist within this range). Procedures Included Maintenance: Scheduled maintenance, oil changes, filter replacements, spark plug checks, decarbonization, general servicing Repair: Engine disassembly and reassembly, component replacement, seal and gasket replacement, internal engine repairs Troubleshooting: Diagnostic procedures for common engine faults, performance issues, starting problems Technical Specifications: Torque values, clearances, measurements, tolerances Engine Rebuild: Complete engine teardown, inspection, measurement, component replacement (pistons, rings, bearings, seals, gaskets), and reassembly with torque specifications. Technical Depth Depth: Comprehensive, covering all aspects from basic checks to complete engine rebuilds. Diagnostic Tools: While not explicitly mentioning specialized diagnostic tools, the manual guides troubleshooting through systematic checks and symptom analysis common in mechanical systems. 📊 Manual Specifications File Format Compatibility: Windows & MAC Computers Print Quality Printability: Printable (single pages or entire manual) Binding Type Binding: Digital (No physical binding) Paper Type Paper Quality: N/A (Digital PDF) Access Access: Instant download, usable on multiple devices Licensing Licensing: Full manual, no expiry, no renewal fees ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke, Liquid-Cooled (typically for these models) Bore Stroke 125: Refer to manual for exact specifications (typically around 54mm x 54.5mm for 125) Bore Stroke 144/150: Refer to manual for exact specifications (larger bore for 144/150) Bore Stroke 200: Refer to manual for exact specifications (typically around 64mm x 62.6mm for 200) Power Valve System: Mechanical power valve system (common on 125/150/200 models) - manual will detail inspection, cleaning, and adjustment. Performance Horsepower Range: Typically 30-40+ HP depending on displacement and specific model tune (manual will provide exact figures) Torque Range: Refer to manual for exact specifications Fuel System Carburetor Type: Keihin PWK (common, but manual will confirm specific models) Fuel Type: Unleaded gasoline with appropriate 2-stroke oil pre-mix ratio (manual will specify ratio and oil type) 🔧 Transmission Standard Transmission Type: 6-Speed Manual Optional Optional Gearing: N/A (Manual transmission is standard) Features Clutch Type: Hydraulic actuated wet multi-plate clutch (common, manual will detail) Transmission Oil Spec: Refer to manual for specific KTM transmission oil or equivalent SAE 10W/15W/20W oil viscosity and API service classification. 📐 Dimensions Exterior Vehicle Type: Off-road/Motocross/Enduro Seat Height: Varies by model, refer to manual for specific models Weights Dry Weight: Varies by model, refer to manual for specific models (typically 90-105 kg) Wet Weight: Varies by model, refer to manual for specific models 🛡️ Safety Features Ratings...