1999-2003 KTM 125/200 Enduro Service Manual | Complete 2-Stroke Repair Guide

Instant Digital Download

USD19.95

File Size: Under 200MB | Format: Searchable PDF

Compatibility: Windows, Mac, iOS, Android, Tablets

Download Now

Secure Payment Processing | 24/7 Immediate Access

Professional Off-Road Documentation

This official factory manual provides the exact same technical specifications and repair procedures used by KTM technicians during the peak of 2-stroke enduro dominance. Essential for maintaining these high-performance competition bikes.

Important Competition Notice

This manual contains critical safety information for working on high-performance dirt bikes. Certain procedures should only be performed by experienced technicians.

Complete Coverage Includes:

2-Stroke Engine Rebuild: Detailed procedures for both 125cc and 200cc engines:

Power valve service and adjustment
Crankcase pressure testing
Piston and cylinder inspection

WP Suspension Setup: Complete service for:

48mm USD fork rebuild
PDS shock maintenance
Spring preload adjustment

Pro Tip: The manual includes factory-recommended jetting charts for different altitudes and temperatures.

Competition Preparation: Special procedures for:

Air filter maintenance in dusty conditions
Handguard and skid plate installation
Radiator protection

Models Covered:

125 SX

125 MXC

125 EXC

200 SX

200 MXC

200 EXC

All 1999-2003 model years with the latest 2-stroke technology of that era.

Key Technical Specifications

Engine: 124.8cc/193cc liquid-cooled 2-stroke single
Power: 30-38 HP (varies by model and year)
Transmission: 6-speed wide-ratio (EXC/MXC)
Suspension: WP 43-48mm USD forks / WP PDS shock
Weight: 205-220 lbs (dry, varies by model)

Special Tool Requirements:

The manual includes KTM's recommended tools:

Power valve removal tool
Case splitting tools
Fork seal driver set
Crankcase pressure tester

Frequently Asked Questions

Q: Does this cover both US and European models?

A: Yes, includes all specifications for both markets with emissions differences noted.

Q: Are the power valve settings different for 125 vs 200?

A: Yes, the manual provides specific adjustment procedures for each displacement.

Q: Does it include the factory break-in procedure?

A: Yes, complete with the recommended run-in process for optimal engine life.

Professional Off-Road Repair Knowledge

Get the same technical information used by KTM race teams - available for immediate download!

Download KTM Manual Now

100% Satisfaction Guaranteed | Military-Grade Encryption

SEO-Optimized Long-Tail Keywords:

KTM 125 SX rebuild, 200 EXC power valve adjustment, 2-stroke enduro maintenance, WP PDS shock service, small bore dirt bike torque specs, Austrian off-road manual, KTM Mikuni carb jetting, vintage enduro suspension setup, competition air filter maintenance, 1999-2003 KTM specs