🏷️ Basic Information

Make:

KTM

Model:

200 SX

Model Year:

2003, 2004

Vehicle Type:

Motocross Motorcycle

Generation Identifier:

First Generation (Likely)

Engine Code Common Variant:

LC2 200 (Single-cylinder, 2-stroke)

👋 Introduction

Vehicle Segment:

Performance Motocross (2-stroke)

Target Audience:

Motocross racers, off-road enthusiasts, mechanics specializing in performance dirt bikes.

Key Competitors:

Yamaha YZ250, Honda CR250, Suzuki RM250, Kawasaki KX250 (all 2-stroke models of the era).

Ktm Positioning:

KTM was establishing its reputation for high-performance, off-road focused European motorcycles known for their robust engines and advanced suspension (often WP).

Engine Configuration:

Lightweight and potent 2-stroke engine, known for its strong mid-range and top-end power delivery, making it competitive in motocross.

Suspension Quality:

Typically equipped with high-quality WP Suspension components, offering excellent adjustability and performance for aggressive riding.

Handling Characteristics:

Agile and responsive handling due to a well-designed chassis and suspension, enabling precise control on the track.

Durability Reputation:

KTM's 'Ready to Race' philosophy implies a focus on durability and performance suitable for demanding racing conditions.

📋 Manual Details

Coverage Scope:

All Models, Engines, Trims, Transmissions

Estimated Page Count:

300-400 (Typical for comprehensive workshop manuals of this era)

Manual Type:

Workshop Repair Service Manual

Language:

English

Digital Format:

PDF Download

📖 Manual Coverage

Engine:

Top-end rebuild (cylinder, piston, rings), bottom-end rebuild (crankshaft, connecting rod, bearings), cooling system (if liquid-cooled), lubrication system, fuel delivery (carburetor overhaul, jetting), exhaust system, ignition system (CDI, spark plug), starting system (kick-start mechanism).

Transmission:

Gearbox disassembly and assembly, clutch operation and maintenance (wet multi-plate), shift mechanism, lubrication.

Chassis And Suspension:

Frame inspection, front fork (WP Suspension, disassembly, seal replacement, oil level/viscosity, adjustments), rear shock absorber (WP Suspension, linkage system, rebuild, adjustments), swingarm, bearings.

Brakes:

Hydraulic disc brakes (front and rear), caliper overhaul, master cylinder maintenance, pad replacement, fluid flush and bleed (DOT 4 recommended), rotor inspection.

Electrical System:

Wiring diagrams, lighting (headlight, taillight, brake light), horn, battery maintenance, stator and ignition coil testing, troubleshooting electrical faults.

Fuel System:

Fuel tank maintenance, petcock operation, carburetor specifications (e.g., Keihin PWK), jetting recommendations for altitude and temperature, air filter service.

Bodywork And Controls:

Seat removal, handlebar and lever adjustments, footpeg maintenance, plastic panel removal and installation, graphics.

Preventative Maintenance:

Regular inspection points, lubrication schedules, chain adjustment and cleaning, air filter cleaning/replacement, spark plug inspection and replacement, coolant checks (if applicable), brake fluid checks.

Troubleshooting:

Diagnostic flowcharts for common starting issues, poor performance, electrical faults, cooling system problems, clutch and transmission issues, braking system faults.

Engine Rebuild:

Detailed step-by-step instructions for complete engine disassembly, cleaning, inspection of wear limits, component replacement (piston, rings, gaskets, seals, bearings), and reassembly with torque specifications.

Suspension Service:

Fork seal replacement, fork oil type and quantity, fork spring preload adjustment, shock absorber linkage lubrication and maintenance.

Carburetor Tuning:

Jetting charts, mixture screw adjustments, float height settings, idle speed adjustments for optimal performance in various conditions.

Brake System Maintenance:

Brake bleeding procedures, pad replacement, caliper piston service, master cylinder seal replacement.

Diagnostics Capability:

Advanced diagnostic procedures, fault code interpretation (if applicable via specific tools or indicators), component testing with multimeter specifications.

Repair Complexity:

Covers everything from basic adjustments and fluid changes to full engine and transmission rebuilds, including suspension and brake system overhauls.

Specification Detail:

Provides critical torque specifications for all fasteners, fluid capacities, recommended fluid types and viscosities, electrical component resistance values, and engine clearance specifications.

📊 Manual Specifications

File Type:

Portable Document Format (PDF)

Searchability:

Likely text-searchable if the original document was digitized properly, allowing quick access to specific information.

Print Clarity:

Dependent on the source digitization, but typically good for detailed diagrams and text.

Diagram Quality:

Includes detailed exploded views and schematics crucial for assembly/disassembly and part identification.

Binding Method:

N/A (Digital PDF)

Paper Quality:

N/A (Digital PDF)

⚙️ Engine Specifications

Engine Type:

2-stroke, single-cylinder, reed valve induction

Displacement:

194 cc (approximately)

Bore X Stroke:

Approx. 66 mm x 57 mm (typical for this class)

Cooling System:

Liquid-cooled

Horsepower Estimate:

Approx. 35-40 HP (at crankshaft, depending on tuning)

Torque Estimate:

Approx. 22-25 lb-ft (at crankshaft, depending on tuning)

Carburetor Model:

Keihin PWK 38 (typical for this model and era)

Fuel Type:

Unleaded gasoline (minimum 95 RON), mixed with 2-stroke oil

Oil Mixing Ratio:

Typically 40:1 or 50:1 with high-quality 2-stroke synthetic oil, as specified in the manual.

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate clutch

Gear Ratios:

Specific ratios detailed in manual, optimized for motocross performance.

Final Drive:

Chain drive (sprocket sizes specified in manual).

📐 Dimensions

Wheelbase:

Approx. 57.3 inches (1455 mm)

Seat Height:

Approx. 38.0 inches (965 mm)

Dry Weight:

Approx. 209 lbs (95 kg)

Fuel Tank Capacity:

Approx. 2.6 gallons (9.8 liters)

🛡️ Safety Features

Crash Test Ratings:

N/A (Motorcycles are not typically subject to the same crash testing standards as passenger vehicles).

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Chassis Design:

Chromoly steel frame designed for rigidity and impact resistance.

Handguards:

Standard fitment on SX models to protect hands and levers from roost and impacts.

💡 Technology Features

Infotainment System:

N/A (Motocross motorcycle, no infotainment features).

Electronic Aids:

N/A (No electronic rider aids like traction control or ABS on this model).

Connectivity Features:

N/A (No connectivity features).

🔧 Maintenance

Oil Change Engine Transmission:

Manual specifies regular checks and changes for gearbox oil (e.g., every 10-15 hours of riding or annually). Engine oil is mixed with fuel for 2-strokes.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours of riding or after each event).

Spark Plug Replacement:

Inspect at regular intervals (e.g., every 10-20 hours), replace as needed. Specific plug type (e.g., NGK BR8EG) and gap specified.

Top End Rebuild:

Recommended every 50-100 hours of hard riding/racing, or when compression drops, as indicated by the manual.

Gearbox Oil Type:

API GL-4 or GL-5, SAE 75W/80 or 80W/90 gear oil. Specific KTM recommendations in manual (e.g., Motorex Gear Oil).

Coolant Type:

Ethylene glycol-based coolant, typically 50/50 mix with distilled water. Specific KTM coolant may be recommended.

Brake Fluid Type:

DOT 4 brake fluid.

Common Wear Items:

Piston rings, clutch plates, wheel bearings, steering head bearings, fork seals, swingarm bushings.

Carburetor Tuning Sensitivity:

2-stroke carburetors can be sensitive to altitude, temperature, and humidity changes, requiring periodic jetting adjustments for optimal performance.

Power Valve Issues:

The mechanical power valve system can accumulate carbon and require cleaning and proper function checks to maintain peak performance.

📚 Vehicle History

Ktm Legacy:

KTM AG, an Austrian manufacturer, has a long history in off-road motorsports, starting with motorcycle production in the 1950s. Known for its dominance in Enduro and Rally racing.

200 Sx Lineage:

The 200 SX represented a move by KTM to offer a potent 2-stroke in the 200cc class, bridging the gap between 125cc and 250cc machines, popular for its manageable power with exciting performance.

Manufacturing Location:

Austria (KTM's primary manufacturing base)

Key Production Years:

The 200 SX model line existed for several years, with the 2003-2004 models being part of a specific generation.

🏆 Awards & Recognition

Motorsport Success:

KTM has a strong legacy in motorsport, and models like the 200 SX have been raced successfully at various levels, contributing to the brand's performance reputation.

Magazine Reviews:

While specific awards for the 2003-2004 200 SX are hard to pinpoint retrospectively, reviews from motorcycle magazines of the era would have highlighted its competitive power, handling, and WP suspension.

Emissions Certification:

Meets relevant emissions standards for off-road motorcycles of its production era. Manual may contain specific details on emissions-related components.