Category:
        
        
            Motocross Competition
        
     
    
        
            Target Audience:
        
        
            Enthusiasts, amateur racers, professional mechanics working on KTM 200 SX models
        
     
    
    
        
            Segment:
        
        
            2-stroke motocross bikes, 125cc-250cc class (competes with Yamaha YZ125/YZ250, Honda CR125R/CR250R, Suzuki RM125/RM250, Kawasaki KX125/KX250)
        
     
    
    
        
            Engine Type:
        
        
            Liquid-cooled, 2-stroke, single-cylinder with Reed Valve Intake
        
     
    
        
            Suspension:
        
        
            High-performance WP USD front forks and WP PDS rear shock absorber, renowned for their adjustability and durability
        
     
    
        
            Brakes:
        
        
            Premium Brembo hydraulic disc brakes front and rear
        
     
    
    
        
            Utility:
        
        
            Essential for proper maintenance, repair, and optimization of the KTM 200 SX
        
     
 
    
    
    
        
            Primary Coverage:
        
        
            Service, Repair, Workshop
        
     
    
        
            Engine Coverage:
        
        
            Engine overhaul, tuning, diagnostics
        
     
    
        
            Chassis Coverage:
        
        
            Frame, suspension, steering, wheels, tires
        
     
    
        
            Electrical Coverage:
        
        
            Wiring diagrams, ignition, lighting, charging system
        
     
    
        
            Brake Coverage:
        
        
            Brake system maintenance and repair
        
     
    
    
        
            Estimated Pages:
        
        
            Refer to specific manual for exact count (typically 300-500 pages for this type of manual)
        
     
    
    
        
            Type:
        
        
            Workshop Service Repair Manual
        
     
    
    
    
    
 
    
    
    
        
            Engine Mechanical:
        
        
            Top end (cylinder, piston, rings, head), bottom end (crankshaft, connecting rod, bearings), valve timing, lubrication system
        
     
    
        
            Fuel System:
        
        
            Carburetor (Mikuni VM28) disassembly, cleaning, adjustment, jetting; fuel tank, fuel lines, fuel filter
        
     
    
        
            Ignition System:
        
        
            CDI ignition system, spark plug selection and gap, ignition timing checks
        
     
    
        
            Cooling System:
        
        
            Liquid cooling system operation, radiator, water pump, thermostat, coolant specifications
        
     
    
        
            Exhaust System:
        
        
            Expansion chamber, muffler maintenance
        
     
    
        
            Transmission:
        
        
            Clutch (hydraulic actuation), gearbox (6-speed), gear oil specifications and change intervals, shifting mechanism
        
     
    
        
            Suspension Front:
        
        
            WP USD (Upside Down) forks: disassembly, inspection, oil change, seal replacement, spring preload adjustment, damping adjustments
        
     
    
        
            Suspension Rear:
        
        
            WP PDS (Pressure Damping System) monoshock: disassembly, inspection, oil change, seal replacement, spring preload, damping adjustments, linkage service
        
     
    
        
            Brakes Front:
        
        
            Brembo hydraulic disc brake system: caliper service, pad replacement, fluid flush (DOT 4), master cylinder service, rotor inspection
        
     
    
        
            Brakes Rear:
        
        
            Brembo hydraulic disc brake system: caliper service, pad replacement, fluid flush (DOT 4), master cylinder service, rotor inspection
        
     
    
        
            Wheels And Tires:
        
        
            Spoke maintenance, rim inspection, tire pressure recommendations, tire size specifications
        
     
    
        
            Electrical System:
        
        
            Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting (headlight, taillight, brake light), horn
        
     
    
        
            Frame And Bodywork:
        
        
            Frame inspection, plastic panel removal and installation, seat, fuel tank removal and installation
        
     
    
    
        
            Routine Maintenance:
        
        
            Oil changes, filter replacements (air, oil), chain cleaning and lubrication, spark plug inspection/replacement, tire pressure checks
        
     
    
        
            Engine Rebuild:
        
        
            Complete engine disassembly, inspection of wear limits, part replacement, reassembly, torque specifications
        
     
    
        
            Carburetor Tuning:
        
        
            Pilot jet, main jet, needle position, air screw adjustments for optimal performance and emissions
        
     
    
        
            Suspension Setup:
        
        
            Dialing in suspension for different riding conditions and rider weights
        
     
    
        
            Troubleshooting:
        
        
            Diagnostic flowcharts for common issues (e.g., hard starting, poor running, electrical faults)
        
     
    
        
            Brake Bleeding:
        
        
            Proper procedure for removing air from the hydraulic brake system
        
     
    
        
            Clutch Adjustment:
        
        
            Hydraulic clutch lever free play adjustment
        
     
    
        
            Wheel Bearing Service:
        
        
            Inspection, cleaning, greasing, and replacement of wheel bearings
        
     
    
    
        
            Depth:
        
        
            Comprehensive: Covers all aspects from basic maintenance to complete engine and chassis overhauls.
        
     
    
        
            Diagnostic Tools:
        
        
            While not explicitly listing diagnostic tools, the manual provides the information necessary for understanding component functions and diagnosing issues through systematic checks.
        
     
    
        
            Torque Specifications:
        
        
            Detailed torque values for all critical fasteners
        
     
    
        
            Wear Limits:
        
        
            Precise measurements for component wear limits (e.g., piston diameter, bore diameter, connecting rod big end play)
        
     
 
    
    
    
        
            Type:
        
        
            Liquid-cooled, 2-stroke single-cylinder
        
     
    
        
            Bore X Stroke:
        
        
            64 mm x 62.4 mm (approximate, refer to manual for exact specification)
        
     
    
    
        
            Compression Ratio:
        
        
            Approximately 8.4:1 (refer to manual for exact specification)
        
     
    
        
            Intake System:
        
        
            Reed valve intake
        
     
    
        
            Exhaust Port Timing:
        
        
            Adjustable (refer to manual for details)
        
     
    
    
        
            Horsepower:
        
        
            Approx. 40-45 HP (at crankshaft, estimated)
        
     
    
        
            Torque:
        
        
            Approx. 22-25 Nm (at crankshaft, estimated)
        
     
    
    
        
            Carburetor:
        
        
            Mikuni VM28SS (or similar, refer to manual for exact specification)
        
     
    
        
            Fuel Type:
        
        
            Unleaded gasoline (RON 95 or higher recommended)
        
     
    
        
            Fuel Mixture:
        
        
            Pre-mix (2-stroke engine oil mixed with gasoline, typically 50:1 ratio - refer to manual for exact ratio)
        
     
    
    
    
        
            Oil Recommendation:
        
        
            High-quality 2-stroke racing oil (refer to manual for specific KTM recommendation)
        
     
 
    
    
    
        
            Engine Oil Change:
        
        
            Gearbox oil: Every 10-15 hours of riding or annually. Refer to manual for exact interval and oil type.
        
     
    
        
            Air Filter Cleaning:
        
        
            After every few rides, or more frequently in dusty conditions.
        
     
    
        
            Spark Plug Inspection:
        
        
            Every 10-20 hours of riding. Replacement as needed based on condition.
        
     
    
        
            Chain Lubrication:
        
        
            After every wash or every few rides.
        
     
    
        
            Suspension Service:
        
        
            Fork oil change: Every 20-30 hours of riding. Full suspension service: Annually or as needed.
        
     
    
    
        
            Gear Oil:
        
        
            KTM recommends specific gearbox oil (e.g., Motorex Gear Oil 10W/40 or equivalent). Check manual for exact specification and capacity.
        
     
    
        
            Brake Fluid:
        
        
            DOT 4 hydraulic brake fluid
        
     
    
        
            Coolant:
        
        
            Distilled water and anti-freeze (50/50 mix). Refer to manual for specific anti-freeze type and capacity.
        
     
    
    
        
            Common Wear Items:
        
        
            Clutch plates, piston rings, spark plug, wheel bearings, chain and sprockets, fork seals.
        
     
    
        
            Carburetor Clogging:
        
        
            Can occur if fuel is left stagnant for extended periods or if fuel quality is poor.
        
     
    
        
            Suspension Leaks:
        
        
            Fork seal and shock seal failures can occur with heavy use or impact damage.