KTM 125, 144, 150, 200 SX, SXS, MXC, EGS, EXC, XC (1999-2010) - Comprehensive Maintenance & Repair Guide
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Sample pages from the KTM 125, 144, 150, 200 SX, SXS, MXC, EGS, EXC, XC (1999-2010) - Comprehensive Maintenance & Repair Guide manual
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Models Covered & Key Technical Specifications
125 SX (1999–2010) 125 EXC (1999–2010) 125 EXC SIX DAYS (1999–2010) 125 MXC (1999–2005) (MXC models were often produced only until around 2005) 125 EGS (1999–2000) (EGS models were often produced only until around 2000) 125 XC (2006–2010) 125 XC-W (2007–2010) 144 SX (2007–2008) 150 SX (2009–2010) 150 XC (2010) 200 EXC (1999–2010) 200 EXC SIX DAYS (1999–2010) 200 MXC (1999–2005) 200 EGS (1999–2000) 200 XC (2006–2010) 200 XC-W (2007–2010)
Professional Workshop Service Manual & Technical Specifications
KTM 125 / 144 / 150 / 200 — Engine & Electrical Reference Manual (SX/SXS/MXC/EGS/EXC/XC/XC-W, 1999–2010) | Art. No. 3.206.062-E
Built around KTM’s 2-stroke 125–200cc platform, this factory document covers the SX, SXS, MXC, EGS, EXC, EXC Six Days, XC, and XC-W families across model years 1999–2010. Fit is anchored by the update/edition structure and the engine-number first-digit year gates, so the correct model-year track can be matched before relying on the specification pages.
Covered platforms and capacities
- Displacement group: 125 / 144 / 150 / 200
- Model families named: SX, SXS, MXC, EGS, EXC, EXC Six Days, XC, XC-W
- Year span: 1999–2010 (loose-leaf update structure)
Year gating you can verify from the engine number
The update index maps model years by the first digit of the engine number:
- 1999 → first digit “9”
- 2000 → “0” | 2001 → “1” | 2002 → “2”
- 2003 → “3” | 2004 → “4” | 2005 → “5”
- 2006 → “6” | 2007/2008 → “7” / “8”
- 2009/2010 → “9” / “0”
What’s inside (chapter architecture)
A 12-part chapter map separates the content into discrete domains: service information, general information, engine R&I, engine teardown/assembly, component service, electrical, fuel system, technical specifications, periodic maintenance schedule, and wiring diagrams—plus a structured index layout designed for binder/loose-leaf updates.
Reference markers you’ll see repeatedly
- Document identifier on cover: Art. No. 3.206.062-E
- Update path lists multiple revision items leading up to the 2009/10 scope
- Consumables and locking compounds are specified by product name and type (e.g., Loctite 243 blue)
- Engine hardware sections include measurable boundaries for crankshaft, cylinder, piston, and clutch wear criteria
Factory identifiers and spec anchors (quick scan list)
- Edition marker shown: 07/2009
- Crankshaft journal runout limit listed as a maximum value
- Crankshaft web outer dimension is specified with a tolerance band
- Cylinder diameter classes are split by model-year break (e.g., 125cc “up to 2000” vs “from 2001” ranges)
- Piston sizing is mapped to cylinder diameter windows by piston-size index
Workshop reference highlights
The special-tools pages list KTM tool numbers and thread specs (including a Kokusan rotor extractor M27×1), while engine internals are supported by wear-limit and sizing tables (piston clearance, ring end-gap maximum, cylinder diameter windows, clutch disc thickness limits). Electrical and wiring content appears as a dedicated chapter, with wiring diagrams separated into their own section for fast navigation.
Document quick facts (for matching)
A loose-leaf/binder format is indicated, with explicit “replace/insert page” guidance and a revision chain that ties older base editions to later update packs—useful when the goal is aligning the book’s scope to a specific year band within the 1999–2010 range.
Fit-critical markers you can confirm at a glance
- Art. No. 3.206.062-E on the cover
- Model-family block: SX/SXS/MXC/EGS/EXC/XC/XC-W
- Capacity group: 125/144/150/200
- Year gates via engine-number first digit (1999–2010 mapping)
Reference details you’ll keep returning to
- Tooling list with KTM part numbers (engine stand, clutch holder, flywheel holding tools, rotor extractor)
- Numeric tolerances for crankshaft, cylinder, piston, and clutch-wear limits
- Wiring diagram section separated from general electrical pages for faster lookup
Practical scope boundary
Coverage is centered on the engine-platform and its supporting systems (electrical, fuel, cooling/lubrication references, specifications, and wiring diagrams) for the named KTM off-road model families across the 1999–2010 model-year map.
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