KTM 200 SX SXS MXC 1999-2006 Workshop Service Manual

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Taper: Motorcycle

Distributeur:

UGS: 72523

Mots clés: 1999 2000 2001 2002 2003 2004 2005 2006 KTM KTM 200 MXC KTM 200 SX KTM 200 SXS Misc Motorcycle Motorcycles

Variantes de produits

Description

This workshop service manual covers the 200 SX, SXS, and EXC models produced between 1999 and 2006. These performance-oriented off-road motorcycles are renowned for their lightweight chassis, potent 2-stroke power delivery, and agile handling, making them a staple in motocross and competition. The SXS variants, in particular, often represented factory-prepped race editions, reflecting a strong heritage in off-road racing and commitment to delivering competitive machinery. This comprehensive 217-page manual provides detailed guidance for owners, mechanics, and technicians on the maintenance, repair, and troubleshooting of these models. It covers all essential systems, including in-depth engine overhaul procedures for the 2-stroke powerplant, transmission servicing, chassis inspection and repair, and electrical system diagnostics. Specific sections address suspension servicing, brake system maintenance, and routine procedures, ensuring that users can effectively maintain their vehicle's peak performance and longevity.

🏷️ Basic Information

Identification

Make:

Model:

200 SX / SXS / EXC

Generation

Production Years:

1999-2006

Codes

Model Codes:

SX, SXS, EXC (Note: EXC is often grouped with SX models for service in this era, though it's a different variant)

👋 Introduction

Market Position

Segment:

Performance Motocross / Off-Road Competition

Competitive Analysis

Competitors:

Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (during the specified model years).

Key Features

Vehicle Strengths:

Lightweight chassis, potent 2-stroke power delivery, strong suspension performance (WP), agile handling characteristics. The SXS variants were often factory-prepped race editions.

Manual Value

Target Audience:

Enthusiast owners, home mechanics, and professional technicians working on KTM 200 SX, SXS, and EXC models from 1999 to 2006.

Benefits:

Provides essential information for maintaining peak performance, diagnosing issues, and executing repairs, saving time and money compared to relying solely on dealer services.

📋 Manual Details

Coverage Areas

Engine Coverage:

2-stroke engine overhaul, top-end and bottom-end rebuild, carburetor tuning, ignition system, cooling system (if applicable to specific variants).

Transmission Coverage:

Clutch service, gearbox inspection and repair, shift mechanism, gear ratios.

Chassis Coverage:

Frame inspection, suspension (forks, rear shock), swingarm, linkage, steering head bearings, wheel bearings, brake system overhaul, cooling system maintenance.

Electrical Coverage:

Wiring diagrams, lighting system, ignition system, battery maintenance, troubleshooting electrical faults.

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Management:

Comprehensive coverage of the 2-stroke engine, including carburetor settings (e.g., Keihin PWK), jetting recommendations, reed valve maintenance, cylinder and piston inspection, crankshaft bearing replacement, and exhaust system tuning.

Suspension And Handling:

Detailed procedures for KTM's renowned WP Suspension components, including fork seal replacement, oil changes, spring rate identification, rear shock absorber servicing, linkage maintenance, and steering head bearing adjustment.

Braking System:

Service procedures for hydraulic disc brakes (front and rear), including caliper overhaul, master cylinder service, brake fluid replacement (DOT 4 typically), pad inspection and replacement, and bleeding procedures.

Cooling System:

Maintenance and servicing of the liquid cooling system, including radiator care, hose inspection and replacement, water pump seal inspection, and coolant type recommendations.

Fuel And Ignition:

Carburetor disassembly, cleaning, and reassembly; ignition coil testing, spark plug selection and gap settings, CDI unit troubleshooting.

Procedures Included

Routine Maintenance:

Chain cleaning and lubrication, air filter cleaning and oiling, spark plug replacement, general inspection checklists.

Engine Rebuild:

Complete top-end rebuilds (piston, rings, cylinder), bottom-end rebuilds (crankshaft, bearings, seals), cylinder head service, and porting information for performance enhancement.

Transmission Overhaul:

Gearbox disassembly, inspection of gears and shift forks, clutch plate replacement, pressure plate adjustments, and lubrication.

Suspension Servicing:

Fork leg disassembly, oil viscosity and level specifications, seal installation, shock absorber charging and valving adjustments (where applicable).

Troubleshooting Guides:

Diagnostic charts for common engine performance issues, electrical faults, starting problems, and suspension malfunctions, with step-by-step diagnostic procedures.

Technical Depth

Depth:

Comprehensive, covering all aspects from basic maintenance and adjustments to complete engine, transmission, and suspension overhauls. Includes detailed torque specifications, clearances, and diagnostic procedures.

📊 Manual Specifications

File Format

Quality:

High-resolution PDF, ensuring clear diagrams and text. Searchable text for quick information retrieval.

Print Quality

Printability:

Designed for easy printing of individual sections or the entire manual for workshop use.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, single-cylinder

Displacement:

Approx. 193 cc (exact may vary slightly by year/model designation)

Bore X Stroke:

Typically around 62.5 mm x 65 mm

Cooling System:

Liquid-cooled

Fuel Delivery:

Carburetor (commonly Keihin PWK 36 or similar)

Performance

Horsepower Estimate:

Estimated 35-40+ HP depending on tune and specific model variant (SX vs. SXS).

Torque Estimate:

Torque figures not typically emphasized in marketing for this class, but focused on broad powerband.

Fuel System

Recommended Fuel:

Unleaded gasoline with a minimum octane rating of 95 (RON+MON)/2 or higher. Premix with high-quality 2-stroke oil.

Air Filter:

High-flow, washable foam air filter. Requires regular cleaning and oiling.

Engine Internals

Piston Type:

Typically a single-ring, performance-oriented piston.

🔧 Transmission

Standard

Type:

6-speed manual transmission

Clutch:

Hydraulically actuated, multi-plate wet clutch

Features

Gear Ratios:

Specific gear ratios are detailed in the manual for each model year and potentially variant.

Lubricant:

Manual will specify KTM's recommended gearbox oil or equivalent SAE 10W/50 or 15W-50 transmission oil.

📐 Dimensions

Exterior

Wheelbase:

Varies slightly by year, generally around 1440-1470 mm.

Weights

Dry Weight:

Around 95-100 kg, depending on specific model and equipment.

Fuel Tank Capacity:

Typically 7-9 liters.

Suspension Travel

Front Travel:

Approximately 280-300 mm (WP USD forks).

Rear Travel:

Approximately 300-330 mm (WP PDS or linkage-driven mono-shock).

🛡️ Safety Features

Ratings

Safety Standards:

Competition off-road motorcycles are not typically subjected to the same safety testing and ratings as street vehicles. Focus is on rider control and machine durability.

Active Features

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Passive Features

Frame Construction:

Strong chromoly steel frame for durability and rider feedback.

💡 Technology Features

Infotainment

Infotainment System:

Not applicable. This is a competition off-road motorcycle with minimal electronic amenities. Focus is on performance and rider feedback.

Driver Assistance

Assistance Features:

Not applicable. No electronic rider aids such as ABS or traction control.

Connectivity

Connectivity Options:

Not applicable.

Engine Tuning

Power Valve:

Features an exhaust power valve system (often controlled by centrifugal weight or diaphragm) to broaden the powerband. The manual will detail its inspection and adjustment.

🔧 Maintenance

Service Intervals

Oil Change Transmission:

Refer to manual for specific hours/conditions, but typically after intensive use or at regular intervals (e.g., every 10-20 engine hours).

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (after every few rides).

Top End Rebuild:

Highly dependent on usage. Can range from 40-100+ engine hours for piston/rings, and significantly more for cylinder/crankshaft bearings.

Fluid Specifications

Coolant:

High-quality, anti-freeze coolant suitable for aluminum engines. Typically a 50/50 mix with distilled water.

Brake Fluid:

DOT 4 hydraulic brake fluid.

Known Issues

Common Wear Items:

Clutch plates, piston rings, top-end components, wheel bearings, steering head bearings, suspension seals are common wear items in high-performance off-road use.

Jetting Sensitivity:

2-stroke engines of this era can be sensitive to jetting changes based on altitude, temperature, and humidity. Proper tuning is crucial for optimal performance and engine longevity.

📚 Vehicle History

Brand Heritage

Ktm Offroad Legacy:

KTM has a long and successful history in off-road racing, known for building competitive and robust machinery. This era represented a significant period of growth and dominance in motocross and enduro.

Model Evolution

200 Sx Development:

The 200 SX model was developed to offer a blend of the agility of a 125cc class bike with more tractable power, bridging the gap between the 125 and 250 classes. SXS models were often factory-tuned for enhanced racing performance.

Production

Manufacturing Location:

Austria (KTM headquarters and primary manufacturing)

🏆 Awards & Recognition

Recognitions

Motocross Wins:

KTM models from this era consistently achieved success in amateur and professional motocross and supercross racing. Specific wins for the 200 SX/SXS variants would be documented by racing publications of the time.

Ratings

Performance Reviews:

Generally praised for their potent engines, excellent suspension, and agile chassis by contemporary motorcycle publications.