KTM 125 200 SX MXC EXC 1999 2000 2001 2002 2003 FACTORY SERVICE REPAIR MANUAL + WIRINGS

KTM 125 200 SX MXC EXC 1999 2000 2001 2002 2003 FACTORY SERVICE REPAIR MANUAL + WIRINGS

1999-2003

 

Model: KTM 125, 200, SX, MXC, EXC

Loaded with Hi Resolution illustrations, instructions, photos, and diagrams, complete to service and repair your motorbike. 

 

 

TABLE OF CONTENTS:

1 SERVICE-INFORMATIONS

2 GENERAL INFORMATION

3 REMOVING AND REFITTING ENGINE

4 DISASSEMBLING ENGINE

5 SERVICING INDIVIDUAL COMPONENTS

6 ASSEMBLING ENGINE

7 ELECTRICAL

8 FUEL SYSTEM

9 TECHNICAL SPECIFICATIONS

10 PERIODIC MAINTENANCE SCHEDULE

11 WIRING DIAGRAMS

 

MANUALS COVER:

 

OPERATING RANGES OF THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . .2-2

CARBURETOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3

BLEEDING OF THE HYDRAULIC CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . .2-4

OIL PUMP ADJUSTING –

MODELS WITH SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .2-5

CHECK OF EXHAUST CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6

REMOVING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

REFITTING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

SPECIAL TOOLS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

DRAINING THE GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

DISMOUNTING THE CLUTCH SLAVE CYLINDER . . . . . . . . . . . . . . . . . . . . .4-3

CYLINDER HEAD, CYLINDER, PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3

IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4

REED VALVE HOUSING, INTAKE FLANGE AND CLUTCH COVER . . . . . . . . .4-5

REED VALVE HOUSING, INTAKE FLANGE AND OIL PUMP

MODELS WITH SEPARATE LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . .4-6

REMOVING CLUTCH AND PRIMARY DRIVE . . . . . . . . . . . . . . . . . . . . . . . .4-6

SHIFT DRUM LOCATING, KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7

DIVIDING THE ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-8

REMOVING SHIFT MECHANISM AND TRANSMISSION . . . . . . . . . . . . . . . .4-9

REMOVING CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9

RIGHT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

LEFT HOUSING HALF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

CRANKSHAFT WEBS – MEASURE OUTER DIMENSION . . . . . . . . . . . . . . . .5-4

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

PISTON RING END GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-4

CHECKING CYLINDER FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

NIKASIL COATING OF CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

DISMOUNTING AND CHECKING THE EXHAUST CONTROL

SYSTEM IN THE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6

PREASSEMBLING THE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

PREASSEMBLING THE CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

PREASSEMBLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11

CHECKING CLUTCH FOR WEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12

REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

PREASSEMBLING THE KICKSTARTER SHAFT . . . . . . . . . . . . . . . . . . . . . . .5-14

SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

PREASSEMBLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16

TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

ASSEMBLING THE MAIN SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-17

ASSEMBLING THE COUNTERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18

IGNITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-19

CHECK STATOR AND PULSE GENERATOR . . . . . . . . . . . . . . . . . . . . . . . . .5-19

MOUNTING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

TRANSMISSION SHAFT, SHIFT MECHANISM . . . . . . . . . . . . . . . . . . . . . . . .6-2

ASSEMBLING THE ENGINE HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

ENGINE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3

SHIFT DRUM LOCATING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

KICKSTARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

PRIMARY DRIVE, CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

CLUTCH DISCS, PRESSURE CAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6

OIL PUMP, REED VALVE HOUSING, INTAKE FLANGE

(SEPARATE LUBRICATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-7

REED VALVE HOUSING, INTAKE FLANGE . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

CLUTCH COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8

PISTON, CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

ADJUSTING DIMENSION „X“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9

ADJUSTING THE CONTROL FLAP (DIMENSION „Z“) . . . . . . . . . . . . . . . .6-10

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-10

IGNITION COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

MEASURING DIMENSION „Y“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-11

MOUNTING THE CLUTCH SLAVE CYLINDER . . . . . . . . . . . . . . . . . . . . . . .6-12

FILLING IN THE GEAR OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-12

CHECKING THE VOLTAGE REGULATOR-RECTIFIER (SHINDENGEN) . . . . . .7-2

CHECKING THE VOLTAGE REGULATOR (KOKUSAN) . . . . . . . . . . . . . . . . . .7-2

CHECKING THE CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

IGNITION COIL (KOKUSAN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-2

CDI UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-3

MEASUREMENTS WITH PEAK VOLTAGE ADAPTER

STATIC IGNITION VALUES 125-200 SX, MXC, EXC . . . . . . . . . . . . . . . . . . . . .7-4

STATIC GENERATOR VALUES 125-200 EXC . . . . . . . . . . . . . . . . . . . . . . . . . . .7-6

STATIC IGNITION VALUES/GENERATOR VALUES 125-200 MXC, EXC USA . . . .7-8

STATIC IGNITION VALUES 125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . . . .7-10

STATIC GENERATOR VALUES 125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . .7-12

TROUBLE SHOOTING 125 / 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-2

TECHNICAL SPECIFICATIONS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . . .9-2

TECHNICAL SPECIFICATIONS – CHASSIS 125/200 . . . . . . . . . . . . . . . . . . .9-4

TECHNICAL SPECIFICATIONS – ENGINE 200 ONLY SINGAPORE . . . . . . . . .9-5

BASIC CARBURETOR SETTING – 200 ONLY SINGAPORE . . . . . . . . . . . . . .9-5

MODEL 2000

TECHNICAL SPECIFICATIONS – ENGINE 125 EXE, SUPERMOTO . . . . . . . . .9-6

TECHNICAL SPECIFICATIONS – CHASSIS 125 EXE, SUPERMOTO . . . . . . . .9-7

TECHNICAL SPECIFICATIONS – ENGINE 125/200 SX, MXC, EXC . . . . . . . .9-8

TECHNICAL SPECIFICATIONS – CHASSIS 125/200 SX, MXC, EXC . . . . . . .9-10

MODEL 2001

TECHNICAL SPECIFICATIONS – ENGINE 125 EXE, SUPERMOTO . . . . . . . . .9-6

TECHNICAL SPECIFICATIONS – CHASSIS 125 EXE, SUPERMOTO . . . . . . . .9-7

TECHNICAL SPECIFICATIONS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . .9-11

TECHNICAL SPECIFICATIONS – CHASSIS 125/200 . . . . . . . . . . . . . . . . . .9-13

MODEL 2002

TECHNICAL SPECIFICATIONS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . .9-14

TECHNICAL SPECIFICATIONS – CHASSIS 125/200 . . . . . . . . . . . . . . . . . .9-16

MODEL 2003

TECHNICAL SPECIFICATIONS – ENGINE 125/200 . . . . . . . . . . . . . . . . . . .9-17

TECHNICAL SPECIFICATIONS – CHASSIS 125/200 . . . . . . . . . . . . . . . . . .9-19

CARBURATOR SPECIFICATION

MODEL 1999 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21

MODEL 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-24

MODEL 2001 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-27

MODEL 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-30

MODEL 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-33

LUBRICATION AND MAINTENANCE SCHEDULE

125 / 200 UP TO 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-2

125 / 200 SX, MXC, EXC 2001 / 2002 . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-3

125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-5

125 / 200 SX, MXC, EXC 2003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-7

WIRING DIAGRAMS 1999

125/200 EXC (EUROPE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-2

125/200 EGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-3

125 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-6

WIRING DIAGRAMS 2000

125/200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-8

125/200 EXC (EUROPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-9

125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11

WIRING DIAGRAMS 2001

125/200 EXC (EUROPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13

125/200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15

125 EXE, SUPERMOTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-11

WIRING DIAGRAMS 2002

125/200 EXC (EUROPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-13

125/200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-15

WIRING DIAGRAMS 2003

125/200 EXC (EUROPA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-16

125/200 EXC (USA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-18

 

BONUS !!!  

KTM 125 200 SX/MXC/EXC PARTS CATALOG WITH PART NUMBERS AND PICTURES WITH DESCRIPTIONS

 

 

This manual is the same as the manual used by workshops. Service Manual contains detailed instructions and step by step diagrams for all workshop procedures.

 Language: English 
Format: PDF – Indexed and Searchable

COMPATIBLE WITH ALL WINDOWS & MAC COMPUTERS 
(WINDOWS 11, WINDOWS 10, WINDOWS 8 ETC.) 

Windows/Mac/Tablet/Phone Friendly

 

 

 

• SX (Motocross): The SX was the race-ready version, featuring a snappy powerband, stiffer suspension, and a 19-inch rear wheel.
• MXC (Cross-Country): These models were equipped with wider-ratio gearboxes and larger fuel tanks for endurance races.
• EXC (Enduro): The EXC was the most trail-friendly version, with a smoother power delivery, softer suspension, and an 18-inch rear wheel for better off-road traction. 

• Starting and jetting issues: Since these are carbureted bikes, starting difficulties and poor running are often caused by dirty or clogged jets. Regular carburetor cleaning is essential.
• Overheating: Issues like a clogged radiator or a faulty temperature sensor can cause overheating, leading to stalling.
• Ignition system: Older KTMs can experience issues with the ignition system, including weak spark due to faulty coils, CDI units, or wiring. Some owners have also reported flywheel issues.
• Suspension: The WP 43mm forks on the 2000–2002 models are generally considered inferior to the 48mm forks introduced in 2003.
• Power valve problems: Issues with the power valve can cause a significant loss of power, particularly in the mid-range.
• Leaks: As with any older two-stroke, intake manifold leaks or worn crank seals can cause the engine to run lean. 

• 2000: Upgraded to 43mm inverted forks.
• 2001: Semi-clear fuel tanks became available, though some 2002 models were delivered with the old orange ones.
• 2003: The most significant update in this range.
  • Suspension: Upgraded to new WP 48mm forks.
  • Chassis: The SX model received new bodywork and a one-piece rear fender.
  • Wheels: The front axle and hubs were enlarged. 

• • Compression test: Always do a compression test to check the health of the piston and rings, as top-end wear is common on two-strokes.

 

Inspect for leaks: Check for coolant or oil leaks, particularly around the intake manifold or crank seals.

• Regular maintenance: These high-performance two-strokes require frequent and diligent maintenance. Check service records for evidence of top-end rebuilds and consistent oil changes.
• Upgrade potential: Suspension components on 2000–2002 models can be significantly improved with aftermarket upgrades or a full suspension re-valve.
• Recall checks: While many recalls may no longer be relevant, it is always a good idea to check if any service bulletins or recalls were ever issued for the model you are considering.