KTM 200 SX SXS 1999-2010 Workshop Service Manual for Repair

Precio habitual: $16.99
Precio de venta: $16.99
Precio habitual
Precio unitario: por

23 people are viewing this right now

Tipo: Motorcycle

Proveedor:

SKU: 72522

Etiquetas: 1999 200 SX 200 SXS 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 KTM Misc Motorcycle Motorcycles

Variantes de producto

Descripción

The 200 SX and SXS models, produced between 1999 and 2010, represent a dedication to high-performance off-road motorcycles, often described as "Ready to Race." These motocross machines are engineered for aggressive riding, emphasizing a strong power-to-weight ratio, responsive handling, and advanced suspension capabilities. The 2-stroke, liquid-cooled engine, typically around 193-200cc, delivers characteristic strong mid-range and top-end power, making it a formidable competitor in its class. Known for their robust construction and Austrian manufacturing heritage, these bikes are built to withstand the rigors of competition and demanding off-road terrain. This workshop service manual provides comprehensive technical guidance for the 200 SX/SXS, covering all essential aspects of maintenance, repair, and troubleshooting. The manual details procedures for engine mechanicals, fuel and ignition systems, transmission, clutch, brakes, suspension, and electrical systems. It includes step-by-step instructions for routine maintenance, engine and suspension rebuilds, carburetor tuning, and system diagnostics. With detailed specifications, torque values, and diagnostic charts, this manual serves as an indispensable resource for owners, mechanics, and technicians aiming to maintain the optimal performance and longevity of their 200 SX/SXS motorcycles.

🏷️ Basic Information

Identification

Make:

Model:

200 SX / SXS

Production Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Codes

Chassis Code:

Not specified in product data, typically model-specific designations for off-road motorcycles.

Engine Code:

Not specified in product data, typically model-specific designations for off-road motorcycles.

👋 Introduction

Market Position

Motorcycle Segment:

Motocross/Off-Road Competition

Target User:

Motocross racers, off-road enthusiasts, mechanics, and DIY repair technicians working on KTM 200 SX/SXS models.

Competitive Analysis

Brand Strength:

KTM is renowned for its performance-oriented off-road motorcycles, often referred to as 'Ready to Race.'

Model Competitors:

Competes against other 2-stroke motocross bikes of similar displacement from brands like Yamaha (YZ250), Honda (CR250), Suzuki (RM250), and Kawasaki (KX250) from the same era.

Key Features

Performance Focus:

Designed for aggressive off-road riding, emphasizing power delivery, handling, and suspension performance.

Manual Utility:

Provides the essential technical information required to maintain, diagnose, and repair the KTM 200 SX/SXS, ensuring optimal performance and longevity.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual for Repair

Page Count:

280 pages

Language:

English (assumed for standard workshop manuals unless otherwise specified)

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete overhaul procedures, piston and ring replacement, cylinder head service, valve adjustment (if applicable, though likely a 2-stroke), crankshaft and connecting rod service, lubrication system.

Engine Fuel System:

Carburetor disassembly, cleaning, adjustment, and tuning. Fuel tank, fuel lines, and fuel filter service. Ignition system (spark plug, coil, CDI unit diagnosis and replacement).

Transmission Drivetrain:

Clutch inspection, adjustment, and replacement. Gearbox disassembly and assembly, gear inspection, shifting mechanism service. Chain and sprockets maintenance and replacement.

Suspension Steering:

Front fork (WP USD forks) service, seal replacement, oil changes, and internal component inspection. Rear shock absorber service and adjustments. Steering head bearing service. Swingarm and linkage bearing maintenance.

Brakes:

Hydraulic brake system service for front and rear. Caliper disassembly, piston inspection, seal replacement. Master cylinder service. Brake fluid bleeding procedures. Pad inspection and replacement. Rotor inspection.

Electrical System:

Wiring diagram analysis, troubleshooting common electrical faults. Lighting system (if applicable), horn, battery maintenance. CDI ignition system diagnostics.

Cooling System:

Radiator inspection and cleaning. Coolant type and replacement. Water pump service (if applicable to the specific 200cc variant). Hose inspection and replacement.

Exhaust System:

Exhaust pipe inspection, packing replacement for silencers (mufflers), and proper assembly.

Bodywork Chassis:

Frame inspection for damage. Seat removal and installation. Fuel tank removal and installation. Plastics and fender maintenance. Footpeg and control lever service.

Procedures Included

Routine Maintenance:

Pre-ride checks, oil changes (transmission oil), chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, brake system checks, tire pressure checks.

Troubleshooting:

Diagnostic charts for common running issues, starting problems, electrical faults, and performance complaints. Specific steps to identify root causes.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly, component inspection (e.g., bore condition, piston ring gap), reassembly, and torque specifications.

Suspension Rebuild:

Detailed guide on disassembling and reassembling front forks and rear shock absorbers, including oil levels, type, and damping adjustments.

Carburetor Tuning:

Procedures for adjusting jetting, idle speed, and mixture for optimal performance in various conditions.

Clutch Adjustment:

Correct procedures for adjusting clutch lever free play and ensuring proper engagement/disengagement.

Brake Bleeding:

Step-by-step guide for safely bleeding air from the hydraulic brake systems.

Wheel Bearing Service:

Inspection, cleaning, lubrication, and replacement of wheel bearings.

Steering Head Service:

Inspection and adjustment/replacement of steering head bearings.

Technical Depth

Diagnostic Capability:

Advanced diagnostic procedures for engine performance, electrical systems, and suspension tuning.

Repair Scope:

Comprehensive repair information covering everything from routine maintenance to full engine and component overhauls.

Specifications Detail:

Includes detailed torque specifications, clearances, fluid capacities, and technical data required for accurate repairs and adjustments.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Likely searchable text within the PDF for efficient information retrieval.

Print Quality:

High-resolution graphics and text, suitable for printing individual pages or the entire manual.

Binding Type

Binding Type:

Digital (PDF Download) - No physical binding.

Paper Type

Paper Type:

Not applicable for digital download, but if printed, would typically be high-quality, durable paper.

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-Stroke, Single-Cylinder, Liquid-Cooled (typical for this model era)

Displacement:

Approximately 193-200cc (specific designation varies by sub-model and year)

Bore X Stroke:

Specific figures vary, but commonly around 63 mm x 64 mm for similar KTM 200cc 2-strokes.

Power Delivery:

Known for strong mid-range and top-end power characteristic of KTM 2-stroke engines.

Performance

Horsepower:

Typically in the range of 35-40+ HP, depending on specific year and tuning.

Torque:

Strong torque output, especially in the mid-range for acceleration out of corners.

Fuel System

Carburetor Type:

High-performance carburetor, often Keihin PWK or similar (e.g., 36mm or 38mm).

Fuel Type:

Unleaded gasoline with appropriate 2-stroke oil mixture (pre-mix or Autolube system, typically pre-mix for SX models).

Oil Type:

High-quality 2-stroke synthetic or semi-synthetic engine oil (specific recommendations in manual).

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh sequential manual transmission.

Optional

Optional Gear Ratios:

Not typically offered as an option on SX models; gear ratios are model-specific.

Features

Clutch Type:

Hydraulically actuated multi-plate wet clutch.

Final Drive:

Chain drive (e.g., 520 pitch chain).

Transmission Oil Capacity:

Approx. 0.75 - 1.0 liter (refer to manual for exact specification).

Transmission Oil Type:

Dedicated transmission oil (e.g., SAE 10W/40, high-quality motorcycle gear oil) - specific type in manual.

📐 Dimensions

Exterior

Wheelbase:

Varies by year, typically around 1450-1470 mm.

Seat Height:

Varies by year, typically around 950-970 mm.

Weights

Dry Weight:

Typically around 95-105 kg.

Fuel Tank Capacity:

Approx. 7-9 liters.

Wheels Tires

Front Wheel Size:

21 inches.

Rear Wheel Size:

19 inches.

Front Tire Size:

80/100-21 (common motocross sizing).

Rear Tire Size:

110/90-19 (common motocross sizing).

Bolt Pattern:

Not applicable for spoke wheels with hubs.

🛡️ Safety Features

Ratings

Safety Certification:

Not rated by official bodies like NHTSA or Euro NCAP as it is a competition off-road vehicle. Safety relies on rider skill and proper equipment.

Active Features

Braking System:

Powerful hydraulic disc brakes front and rear, designed for aggressive stopping power.

Suspension Performance:

High-quality adjustable suspension (WP) for optimal control and stability over rough terrain.

Passive Features

Frame Design:

Robust chromoly steel frame for strength and rigidity.

Ergonomics:

Designed for aggressive riding posture and rider control.

💡 Technology Features

Infotainment

Infotainment System:

None (This is a competition off-road motorcycle, focused solely on performance).

Driver Assistance

Driver Assistance Features:

None (No electronic rider aids present).

Connectivity

Connectivity Features:

None (No digital connectivity features).

Engine Management

Ignition System:

CDI (Capacitor Discharge Ignition) for reliable spark generation.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 15-20 hours of riding or annually, whichever comes first (refer to manual for precise interval based on usage).

Air Filter Cleaning:

After every few rides, especially in dusty conditions.

Spark Plug Inspection:

Regularly, typically every 10-15 hours of riding.

Chain Lubrication:

After every ride or every few hours of riding, depending on conditions.

Fluid Specifications

Engine Oil Grade:

Refer to manual for specific 2-stroke oil recommendation (e.g., Motorex, Castrol Power RS).

Transmission Oil Grade:

Refer to manual for specific transmission oil recommendation (e.g., SAE 10W/40 motorcycle gear oil).

Coolant Type:

Ethylene glycol-based antifreeze/coolant mixture with corrosion inhibitors (typically 50/50 mix).

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid.

Known Issues

Common Wear Items:

Piston rings, clutch plates, wheel bearings, suspension seals, and exhaust packing are common wear items requiring periodic replacement.

Carburetor Jetting:

Can require re-jetting based on altitude, temperature, and modifications for optimal performance.

Power Valve Maintenance:

The power valve mechanism (if present) may require cleaning and maintenance to ensure proper operation.

📚 Vehicle History

Brand Heritage

Ktm Heritage:

KTM is an Austrian manufacturer with a strong heritage in off-road racing and a reputation for innovation and performance.

Model Evolution

200 Sx Evolution:

The 200 SX was part of KTM's strategy to offer a potent 2-stroke machine bridging the gap between 125cc and 250cc classes, providing a strong power-to-weight ratio and accessible performance for a wide range of riders.

Sxs Variant:

The 'SXS' designation often indicated factory racing modifications or higher-spec components aimed at a more performance-oriented rider or competition use.

Production

Production Period:

Continuously produced through the 1999-2010 period with various updates and refinements.

Manufacturing Location:

Austria (KTM AG)

🏆 Awards & Recognition

Recognitions

Industry Awards:

KTM motorcycles consistently receive accolades and championships in various off-road racing disciplines, reflecting the inherent performance and capability of their models.

Ratings

Performance Ratings:

Highly rated by enthusiasts and professional riders for their potent engines, sharp handling, and durable construction in their respective eras.