🏷️ Basic Information

Make:

KTM

Model:

200 SX

Production Years Covered:

1999, 2000, 2001, 2002, 2003

Chassis Code:

Specific chassis codes not explicitly detailed in product information, but typical for this era would be 2-stroke motocross designations.

Engine Code Series:

KTM 2-stroke, 200cc class engines.

👋 Introduction

Vehicle Class:

Competition Off-Road (Motocross)

Target Audience:

Motocross riders, mechanics, and workshop technicians focused on the KTM 200 SX.

Competitors:

Yamaha YZ250, Honda CR250, Suzuki RM250, Kawasaki KX250 (during the specified model years).

Key Differentiators:

KTM's typically strong performance, advanced WP suspension, and focus on aggressive off-road riding.

Manual Value Proposition:

Provides comprehensive, factory-authorized repair and maintenance information to keep the KTM 200 SX in peak performance condition.

Vehicle Appeal:

The KTM 200 SX is renowned for its potent 2-stroke powerband and agile handling, making it a favorite for riders seeking an exciting motocross experience.

📋 Manual Details

Engine Overhaul:

Yes

Suspension System:

Yes

Brake System:

Yes

Electrical System:

Yes

Chassis And Frame:

Yes

Cooling System:

Yes

Fuel System:

Yes

Exhaust System:

Yes

Bodywork And Plastics:

Yes

Wheels And Tires:

Yes

Troubleshooting Guides:

Yes

Torque Specifications:

Yes

Wiring Diagrams:

Yes

Maintenance Schedules:

Yes

Estimated Pages:

Hundreds (as stated in product description)

Manual Type:

Factory Service Repair Manual

Language:

English (assumed for factory service manuals in this market)

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Full engine rebuild procedures, including top-end (piston, rings, cylinder), bottom-end (crankshaft, connecting rod, bearings), and associated components.

Engine Management:

Carburetor tuning, jetting, and maintenance; ignition system diagnosis and repair.

Transmission And Drivetrain:

Clutch operation and adjustment, gearbox disassembly and reassembly, chain and sprockets maintenance.

Suspension Forks:

Front fork servicing (oil changes, seal replacement), valving inspection, and adjustment procedures.

Rear Suspension Shock ABSorber:

Rear shock absorber maintenance, adjustment (rebound, compression, preload), and potential rebuild guidance.

Braking System Front:

Front brake caliper, master cylinder, and lever servicing; brake pad replacement and fluid bleeding.

Braking System Rear:

Rear brake caliper, master cylinder, and pedal servicing; brake pad replacement and fluid bleeding.

Electrical System Lighting:

Headlight, taillight, and brake light maintenance and bulb replacement.

Electrical System Ignition:

Spark plug inspection and replacement, CDI unit diagnosis, and stator/flywheel checks.

Electrical System Battery:

Battery inspection, charging, and terminal maintenance (if applicable to this model's electrical system).

Fuel Delivery:

Fuel tank maintenance, petcock operation, and fuel line checks.

Cooling System Radiator:

Radiator cleaning, coolant level checks, and hose inspection.

Exhaust System:

Exhaust pipe and silencer maintenance, including packing replacement for the silencer.

Frame And Swingarm:

Frame integrity checks, swingarm bearing service, and linkage maintenance.

Wheel Bearings:

Front and rear wheel bearing inspection and replacement.

Steering Head:

Steering head bearing adjustment and lubrication.

Preventative Maintenance:

Detailed procedures for routine checks, lubrication, adjustments, and fluid changes at specified intervals.

Diagnostic Procedures:

Step-by-step troubleshooting guides for common performance issues, starting problems, and system malfunctions.

Disassembly And Reassembly:

Comprehensive instructions for dismantling and reassembling all major components and systems for repair or overhaul.

Adjustment Procedures:

Specific guidance on adjusting controls, linkages, suspension settings, and engine components.

Part Replacement:

Detailed instructions for replacing individual parts, including specialized tools and techniques.

Periodic Inspections:

Checklists and guidelines for regular inspections to identify potential problems before they escalate.

Wiring Harness Repair:

Guidance on inspecting, repairing, and rerouting the electrical wiring harness.

Depth Level:

Full Factory Repair & Overhaul

Engine Rebuild Scope:

Complete engine teardown, inspection, measurement, and reassembly for full rebuilds.

Suspension Tuning:

Detailed explanations of suspension adjustments and their impact on handling.

Electrical Diagnosis:

In-depth diagnostic procedures for electrical faults, including resistance and voltage testing.

Special Tool Requirements:

Identification of any special tools required for specific procedures.

📊 Manual Specifications

File Format:

PDF

Print Quality:

High-resolution, suitable for printing professional-quality pages.

Binding Type:

N/A (Digital Download - User prints and binds as desired)

Paper Type:

N/A (Digital Download - User selects paper type upon printing)

⚙️ Engine Specifications

Engine Type:

2-Stroke

Displacement:

193 cc (approximately)

Bore X Stroke:

Specific figures not in product data, but typical for this class is around 62.5mm x 65mm.

Cooling System:

Liquid-cooled

Ignition System:

CDI (Capacitive Discharge Ignition)

Starting System:

Kick-start

Horsepower:

Estimated 35-40 HP range (varies by year and tuning).

Torque:

Specific figures not in product data, but strong mid-range power is characteristic.

Carburetor Type:

Keihin PWK (typically 36mm)

Fuel Type:

Unleaded gasoline (high octane recommended, with 2-stroke oil pre-mix)

Oil Delivery:

Premix (manual mixing of oil and fuel)

🔧 Transmission

Transmission Type:

6-speed manual

Optional Transmission:

N/A (Standard for this model)

Clutch Type:

Hydraulically operated wet multi-plate clutch

Gear Ratios:

Specific gear ratios are detailed within the manual.

📐 Dimensions

Wheelbase:

Specific figures not in product data, but typical for this era is around 57-58 inches.

Dry Weight:

Around 215-225 lbs (98-102 kg).

Fuel Tank Capacity:

Approximately 8-10 liters (2.1-2.6 gallons).

🛡️ Safety Features

Safety Certification:

Not applicable for competition off-road motorcycles in the same way as road vehicles.

Braking System Effectiveness:

Hydraulic disc brakes front and rear, designed for powerful stopping performance.

Frame Strength:

Chromoly steel frame provides a robust and resilient chassis.

💡 Technology Features

Infotainment System:

Not applicable (competition off-road motorcycle).

Driver Assistance Features:

Not applicable (competition off-road motorcycle).

Connectivity Options:

Not applicable (competition off-road motorcycle).

🔧 Maintenance

Oil Change Engine:

Transmission oil change recommended every 10-15 hours of riding. Refer to manual for precise intervals.

Air Filter Cleaning:

Recommended after every few rides, or more frequently in dusty conditions. Manual will detail specific checks.

Spark Plug Replacement:

Check at regular intervals (e.g., every 10-20 hours), replace as needed. Manual provides specifications.

Top End Rebuild:

Typically recommended every 40-60 hours of hard riding, depending on usage. Manual details wear limits and procedures.

Transmission Oil:

KTM recommends specific gear oil for their transmissions; consult manual for part number and viscosity (e.g., Motorex Gear Oil).

Coolant:

Ethylene glycol-based coolant (typically a 50/50 mix with distilled water). Manual will specify type and capacity.

Fork Oil:

Specific viscosity and type (e.g., WP Suspension Fork Oil, often around 5W or 7.5W). Manual will specify quantity and type.

Brake Fluid:

DOT 4 brake fluid.

Common Wear Items:

Piston, piston rings, clutch plates, fork seals, wheel bearings, and chain/sprockets are common wear items on 2-stroke motocross bikes.

Carburetor Tuning Sensitivity:

2-stroke carburetors can be sensitive to altitude, temperature, and humidity changes, requiring occasional jetting adjustments.

Power Valve Maintenance:

The power valve system requires periodic cleaning and lubrication to function correctly, preventing performance degradation.

📚 Vehicle History

Ktm Heritage:

KTM is an Austrian manufacturer with a strong legacy in off-road motorsports, known for its 'Ready to Race' philosophy.

200 Sx Evolution:

The 200 SX was developed as a potent intermediate-displacement motocross bike, bridging the gap between 125cc and 250cc classes, offering a significant power advantage over the 125 without the same raw intensity as a 250.

Manufacturing Location:

Austria (KTM headquarters and primary manufacturing)

🏆 Awards & Recognition

Motorcycle Magazine Reviews:

The KTM 200 SX of this era was generally well-regarded in motorcycle media for its potent engine and handling, often earning positive reviews in motocross publications.

Performance Ratings:

Consistently rated highly for its power-to-weight ratio and agility.

Emissions Certification:

Not applicable for competition off-road motorcycles which are typically not street-legal and exempt from road emissions standards.