Segment:
Motocross/Off-road Competition
Competitors At Time:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (though 200cc class was less direct)
Vehicle Focus:
Lightweight, agile, powerful for its displacement, focused on competitive motocross performance
Value Proposition:
Provides mechanics and owners with the necessary information to maintain, diagnose, and repair the KTM 200 SX accurately.
Engine:
Complete overhaul, diagnosis, tuning, lubrication, cooling system, fuel system, exhaust system
Transmission:
Gearbox inspection, repair, clutch service, lubrication
Chassis:
Frame, suspension (front and rear forks, shock absorber), steering, swingarm, linkages
Brakes:
Hydraulic systems (front and rear calipers, master cylinders, lines), bleeding procedures, pad and rotor replacement
Electrical System:
Wiring diagrams, ignition system, lighting, charging system, troubleshooting electrical faults
Fuel System:
Carburetor service and adjustment, fuel lines, fuel tank maintenance
Cooling System:
Radiator, coolant, thermostat (if applicable for model year)
Bodywork:
Fairings, seat, fenders, decals, general disassembly/reassembly
Maintenance:
Scheduled maintenance tasks, fluid changes, filter replacements, spark plug service, chain adjustment
Troubleshooting:
Diagnostic procedures for common and uncommon issues, fault finding guides
Repair:
Detailed step-by-step instructions for component repair and replacement
Rebuilds:
Engine disassembly and reassembly, carburetor rebuilds, suspension overhauls
Specifications:
Torque values, clearances, fluid capacities, part numbers (where applicable within the manual)
Suspension Adjustment:
Front fork (compression, rebound, preload) and rear shock absorber (compression, rebound, preload) adjustments and servicing.
Wheel And Tire Service:
Tire removal/installation, wheel balancing, spoke tensioning, hub maintenance.
Depth:
Comprehensive (covers from routine maintenance to complete engine and chassis overhauls)
Diagnostic Charts:
Includes detailed troubleshooting flowcharts and diagnostic trees for common problems.
Special Tools:
Lists required special tools for specific procedures (e.g., flywheel puller, clutch holding tool).
Engine Type:
2-Stroke, Single Cylinder
Displacement:
Approx. 193 cc (exact for specific model years should be confirmed within the manual)
Bore X Stroke:
Refer to manual for exact specifications (typically around 62.5mm x 65mm)
Cooling System:
Liquid-cooled
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Cylinder Head:
Read the manual for specific cylinder head configurations and porting details.
Exhaust Port Timing:
Refer to manual for detailed specifications and adjustment procedures (if applicable).
Reed Valve System:
Details on reed block maintenance and replacement.
Horsepower:
Estimated 35-40 HP (varies by year and tuning)
Torque:
Refer to manual for specific torque figures
Carburetor Model:
Keihin PWK (typically 36mm or 38mm, confirm in manual)
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix (e.g., 50:1 ratio, confirm in manual)
Oil Type:
High-quality 2-stroke synthetic or semi-synthetic oil (specific grades in manual)
Transmission Type:
6-speed manual sequential gearbox
Optional Gearbox:
N/A (Standard configuration)
Clutch Type:
Wet multi-plate clutch
Gear Ratios:
Refer to manual for specific ratios
Transmission Oil Type:
Refer to manual for specific transmission oil specifications (e.g., SAE 10W/40, SAE 75W/90)
Gearbox Lubrication:
Specific procedures for draining, filling, and checking gearbox oil levels.
Oil Change Interval:
Refer to manual; typically based on operating hours for off-road use.
Air Filter Cleaning:
Frequent cleaning recommended based on riding conditions (e.g., after every few rides).
Spark Plug Replacement:
Refer to manual, typically 20-40 operating hours or as needed based on inspection.
Clutch Inspection:
Regular inspection of clutch plates for wear and proper operation, as per manual.
Coolant Type:
Ethylene glycol-based antifreeze/coolant (specific mixture ratio and type in manual)
Brake Fluid Type:
DOT 4 hydraulic brake fluid (confirm in manual)
Fork Oil Type And Level:
Crucial specifications for front fork oil viscosity and fill level, detailed in manual.
Common Wear Items:
Piston rings, clutch plates, wheel bearings, chain and sprockets, fork seals due to demanding use.
Performance Tuning:
Carburetor jetting and exhaust modifications are common for optimizing performance, detailed guidance in manual.
Carburetor Issues:
Poor idle, bogging, or fouling are often related to jetting, air leaks, or float height, detailed diagnostic steps provided.
Ignition Problems:
No spark or intermittent spark often relates to stator, CDI unit, or wiring faults, electrical diagrams essential.
Ktm Offroad Legacy:
KTM has a long and successful history in off-road motorcycle racing and manufacturing, known for 'Ready to Race' philosophy.
200 Sx Positioning:
The 200 SX was positioned as a powerful, lightweight 2-stroke motocross bike, offering a blend of 125cc agility with 250cc-like power characteristics, a niche but popular option.
Manufacturing Location:
Austria (KTM headquarters)
