KTM 200 SX 1999-2010 Service Repair Workshop Manual

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Taper: Motorcycle

Distributeur:

UGS: 76724

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

Variantes de produits

Description

The 200 SX is a celebrated motocross machine, produced from 1999 through 2010. Engineered for competitive off-road racing, this 2-stroke, liquid-cooled single-cylinder motorcycle is renowned for its lightweight design, agile handling, and powerful engine, embodying a 'Ready to Race' philosophy. Its performance focus, sharp handling characteristics, and rider-centric ergonomics have placed it as a strong contender in its class against other prominent manufacturers. The 200 SX offers a potent blend of power and maneuverability, making it a formidable choice for motocross enthusiasts and competitors seeking peak performance on the track. This comprehensive service and repair manual provides detailed guidance for the 200 SX, covering all essential aspects of its maintenance and repair. It includes in-depth information on powertrain systems, chassis and suspension, braking systems, and the electrical system. The manual details routine maintenance procedures, troubleshooting common issues, and step-by-step repair and rebuild instructions for all major components. Furthermore, it supplies critical technical data and specifications, such as torque values and fluid capacities. This resource is invaluable for owners and technicians aiming to maintain the vehicle's optimal performance, ensure reliability, and execute accurate repairs.

🏷️ Basic Information

Identification

Make:

Model:

200 SX

Generation

Production Years Covered:

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

Codes

Engine Codes:

Specific engine codes vary by year and sub-model; refer to manual for precise identification. Typically 2-stroke single-cylinder.

👋 Introduction

Market Position

Segment:

Motocross (MX) / Off-road Competition

Competitive Analysis

Competitors:

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

Key Features

Performance Focus:

Lightweight, agile, powerful 2-stroke engine optimized for competitive off-road use.

Handling Characteristics:

Renowned for sharp handling and rider-centric ergonomics, typical of KTM's 'Ready to Race' philosophy.

Manual Value Proposition

Utility:

Essential for owners and mechanics to maintain peak performance, diagnose issues, and perform repairs on the KTM 200 SX.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Repair, Workshop

Page Count

Estimated Page Count:

Detailed page count not provided in product information, but typical comprehensive workshop manuals of this scope can range from 300 to 800+ pages.

Manual Type

Type:

Service/Repair/Workshop Manual

Language

Language:

Likely English, common for international service manuals. Specific language to be confirmed by seller.

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Powertrain:

Engine overhaul, carburetor tuning, exhaust system, cooling system (if applicable), clutch, gearbox, drivetrain.

Chassis And Suspension:

Frame, front fork (WP Suspension or similar), rear shock absorber, swingarm, steering system, wheel bearings.

Brakes:

Front and rear brake systems (hydraulic disc brakes), brake fluid specifications, bleeding procedures, caliper service.

Electrical System:

Ignition system, lighting, battery, wiring diagrams, component testing, troubleshooting.

Body And Trim:

Body panels, seat, fuel tank, plastics, graphics, levers, footpegs.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain adjustment, spark plug service, air filter cleaning/replacement, valve clearance checks (for 4-strokes, though this is a 2-stroke), pre-ride inspections.

Troubleshooting:

Diagnostic procedures for common running issues, electrical faults, mechanical failures.

Repair And Rebuild:

Step-by-step instructions for engine teardown and rebuild, transmission overhauls, suspension servicing, brake caliper rebuilds.

Technical Data And Specifications:

Torque specifications, clearances, fluid types and capacities, electrical component values, engine timings.

Technical Depth

Depth:

Comprehensive. Designed for both routine maintenance and in-depth mechanical repairs and diagnostics, suitable for both amateur and professional mechanics.

📊 Manual Specifications

File Format

File Type:

Print Quality

Resolution And Readability:

Quality depends on the source scan; typically aims for clear text and diagrams. Searchable text functionality is common in good quality PDFs.

Binding Type

Binding:

Not applicable for PDF download.

Paper Type

Paper Quality:

Not applicable for PDF download. Digital format.

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, single-cylinder, reed valve induction

Displacement:

Approximately 193-200cc (specific bore and stroke vary by exact model year).

Bore X Stroke:

Typical for this era might be around 62.5mm x 65mm, but needs manual confirmation.

Cooling System:

Liquid-cooled

Performance

Horsepower:

Estimates range from 35-45 HP, depending on tuning and year. Manual will provide exact figures.

Torque:

Peak torque figures usually in the 25-30 Nm range. Manual will specify.

Fuel System

Carburetor:

Likely Mikuni TM series (e.g., TM38) or Keihin PWK. Manual will detail specific model and jetting.

Fuel Type:

Unleaded gasoline (95-98 RON) mixed with 2-stroke oil. Specific ratio (e.g., 1:40, 1:50) provided in manual.

Engine Internal Components

Piston Type:

2-ring, typically for performance tuning.

Crankshaft Design:

Full crank, often with robust connecting rod for competition use.

🔧 Transmission

Standard

Type:

6-speed manual transmission

Gear Ratios:

Specific ratios will be detailed in the manual for each gear.

Features

Clutch:

Hydraulic-actuated, multi-plate wet clutch.

Final Drive:

Chain drive. Manual will cover chain tension adjustment and lubrication intervals.

Fluid Specifications

Transmission Oil Type:

Specific KTM-recommended transmission oil or suitable high-quality gearbox oil (e.g., SAE 80W/90). Manual will confirm.

📐 Dimensions

Exterior

Wheelbase:

Approx. 1450 mm (57.1 inches), subject to minor variations by year. Manual will confirm.

Ground Clearance:

Typically around 350-380 mm (13.8-15 inches). Manual will provide precise figure.

Weights

Dry Weight:

Around 95-100 kg (209-220 lbs). Manual will specify exact dry weight.

Fuel Capacity:

Typically 7-9 liters (1.8-2.4 US gallons). Manual will detail exact capacity.

Suspension Travel

Front Fork Travel:

Around 280-300 mm (11-11.8 inches). Manual specifies for WP forks.

Rear Shock Travel:

Around 300-320 mm (11.8-12.6 inches). Manual specifies for PDS system or linkage.

🛡️ Safety Features

Ratings

Crash Test Results:

Not applicable to competition dirt bikes. Safety is focused on rider protection through design and rider skill.

Active Features

Braking System:

High-performance hydraulic disc brakes front and rear for effective stopping power. Manual details caliper and rotor specifications.

Passive Features

Frame Construction:

Chromoly steel trellis frame, designed for rigidity and impact resistance.

Ergonomics:

Designed for rider control and balance in aggressive off-road riding.

💡 Technology Features

Infotainment

Features:

N/A for this competition model. Focused on performance, not rider amenities.

Driver Assistance

Features:

N/A. Rider skill is paramount.

Engine Management

Ignition System:

Digital CDI (Capacitor Discharge Ignition) for optimal spark timing across the RPM range. Manual details timing checks and adjustments.

🔧 Maintenance

Service Intervals

Engine Top End:

Piston and ring replacement typically recommended every 50-100 hours of hard use, depending on riding style and maintenance. Manual will provide detailed guidelines.

Oil Change Transmission:

Check and change transmission oil every 10-20 hours of riding or as specified. Manual will list exact interval and procedure.

Air Filter Cleaning:

Clean after every few rides, especially in dusty conditions. Manual will specify.

Fluid Specifications

Coolant:

Pre-mixed or concentrated ethylene glycol-based coolant. Manual specifies type and mixture ratio.

Brake Fluid:

DOT 4 or DOT 5.1 hydraulic brake fluid. Manual will specify.

Known Issues

Common Wear Items:

Clutch plates, piston rings, wheel bearings, suspension seals, chain and sprockets are common wear items on competition dirt bikes.

Carburetor Jetting:

May require adjustments based on altitude, temperature, and humidity. Manual provides baseline jetting and tuning guidance.

Part Numbers

Air Filter Oem Example:

Exact OEM part numbers are model and year specific; refer to manual or parts fiche. Likely a K&N or Twin Air equivalent will be available.

Spark Plug Example:

NGK BR9EG or similar. Manual will confirm correct plug and gap.

📚 Vehicle History

Brand Heritage

Origins:

KTM, founded in Austria, has a strong legacy in off-road motorcycle racing, particularly motocross and enduro.

Model Evolution

200 Sx Development:

The 200 SX was developed as a competitive 200cc class motocross bike, offering a blend of the power of 250cc bikes with the agility of 125cc bikes.

Production

Manufacturing Location:

Primarily Austria.

🏆 Awards & Recognition

Recognitions

Motocross Performance:

KTM models from this era consistently received praise for their performance and competitive edge in professional and amateur motocross and supercross racing.

Ratings

Review Consensus:

Generally rated highly for power delivery, handling, and suspension performance among its class. Manual supports achieving these optimal settings.