menu

0
0
Votre panier
😊 Product added to cart successfully   Product removed to cart successfully
Votre panier est vide !
Continuer les achats
1 2

KTM 200 SX Engine 2003 2004 Service Repair Manual

$16.99
$16.99
This manual covers the 200 SX, a competition motocross motorcycle produced for the 2003 and 2004 model years. Engineered for off-road performance, the 200 SX features a potent 200cc 2-stroke...
24 people are viewing this right now
Taper: Motorcycle
Distributeur:
Ktm
UGS: 94479
Mots clés: 200 SX 2003 2004 KTM Misc Motorcycle Motorcycles
KTM 200 SX Engine 2003 2004 Service Repair Manual
This manual covers the 200 SX, a competition motocross motorcycle produced for the 2003 and 2004 model years. Engineered for off-road performance, the 200 SX features a potent 200cc 2-stroke engine, a robust chromium-molybdenum steel trellis frame, and advanced suspension systems designed for demanding terrain. A strong heritage in motorsports is evident in the 200 SX's agile handling and competitive edge, making it a favored choice for riders focused on motocross and off-road racing. This comprehensive service repair manual provides detailed information essential for the maintenance and repair of your 200 SX. It covers all major systems, including the engine, transmission, fuel system, ignition, cooling, exhaust, chassis, suspension, brakes, and electrical systems. Within its pages, you will find step-by-step procedures for routine maintenance, advanced troubleshooting, and complete engine and suspension overhauls. Critical technical specifications, torque values, and fluid recommendations are also included, ensuring that owners, mechanics, and technicians have the necessary resources to keep the 200 SX performing at its peak.
🏷️ Basic Information
Identification
Make:
KTM
Model:
200 SX
Year:
2003, 2004
Engine Variant:
200cc 2-Stroke
Product Type:
Service Repair Manual
👋 Introduction
Market Position
Segment:
Motocross / Off-Road Competition
Target User:
KTM 200 SX owners, mechanics, and enthusiasts focused on performance and maintenance of their competition dirt bike.
Competitive Analysis
Alternatives:
Service manuals for comparable 125cc-250cc 2-stroke motocross bikes from brands like Yamaha (YZ250), Honda (CR250R), Suzuki (RM250), Kawasaki (KX250).
Key Features
Manual Benefit:
Provides in-depth technical guidance to maintain peak performance and longevity of the KTM 200 SX engine and associated systems.
Format Advantage:
PDF format allows for easy searching, instant access, and viewing on multiple devices, superior to outdated paper manuals.
📋 Manual Details
Coverage Areas
Systems Covered:
Engine, Transmission, Fuel System, Ignition System, Cooling System, Exhaust System, Chassis, Suspension, Brakes, Electrical System, Lubrication System, Troubleshooting, Maintenance
Page Count
Estimated Pages:
200-300
Manual Type
Type:
Service Repair Manual
Language
Language:
English
Format
Format:
PDF
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Complete disassembly, inspection, repair, and reassembly of the 200cc 2-stroke engine, including cylinder, piston, connecting rod, crankshaft, bearings, seals, and gaskets.
Fuel System:
Carburetor (Mikuni VM28 or similar) tuning, jetting, cleaning, and overhaul; fuel tank and petcock maintenance.
Ignition System:
CDI unit, ignition coil, spark plug selection and gap, timing adjustments, stator and rotor inspection.
Transmission And Clutch:
Gearbox internal inspection, gear selection, clutch assembly, clutch plates, springs, and cable adjustment.
Cooling System:
Liquid cooling system, radiator, water pump, hoses, and thermostat operation (if applicable to specific model variant).
Exhaust System:
Exhaust pipe and silencer maintenance, cleaning, and inspection.
Suspension:
Front fork (WP or similar) service, oil levels, seal replacement, damping adjustments. Rear shock absorber service, spring preload, and damping adjustments.
Brakes:
Hydraulic disc brake systems (front and rear), caliper service, brake pad replacement, master cylinder, brake fluid specifications and bleeding procedures.
Electrical System:
Wiring diagrams, lighting circuits, kill switch, battery maintenance, charging system inspection.
Procedures Included
Routine Maintenance:
Oil changes (gearbox), filter cleaning/replacement, chain maintenance, spark plug inspection, air filter cleaning/replacement, general bolt checks.
Troubleshooting:
Diagnosis of common performance issues, starting problems, electrical faults, and mechanical noises with step-by-step diagnostic trees.
Engine Rebuild:
Detailed instructions for top-end and bottom-end engine overhauls, including torque specifications, clearances, and critical assembly steps.
Suspension Overhaul:
Front fork seal and bushing replacement, rear shock absorber seal head service, gas recharging procedures (if applicable).
Brake System Service:
Brake fluid flush and bleeding, caliper piston service, rotor cleaning and inspection.
Technical Depth
Diagnostic Level:
Advanced diagnostic procedures, fault code interpretation (if applicable), measurement of electrical components and mechanical tolerances.
Repair Detail:
Comprehensive step-by-step repair instructions with detailed illustrations and diagrams for all major vehicle systems.
Specifications:
Inclusion of all critical torque values, clearances, fluid capacities, and performance specifications required for accurate repair and tuning.
📊 Manual Specifications
File Format
File Type:
PDF
Searchability:
Searchable text for quick information retrieval.
Print Quality
Print Readability:
High-resolution for clear viewing and printing of diagrams and text.
Binding Type
Binding:
N/A (PDF Format)
Paper Type
Paper:
N/A (PDF Format)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke, single-cylinder
Displacement:
196 cc
Bore X Stroke:
62.5 mm x 65 mm (typical, may vary slightly)
Cooling System:
Liquid-cooled
Lubrication:
Pre-mix fuel or Autolube (check specific model variant for clarity, usually pre-mix for competition models)
Carburetor Model:
Mikuni VM28SS (typical)
Performance
Horsepower:
Approximately 35-40 HP (estimate, actual figures depend on tuning and conditions)
Torque:
Approximately 20-23 lb-ft (estimate)
Fuel System
Fuel Type:
High-octane gasoline (91+ RON or 87+ AKI) mixed with 2-stroke oil
Fuel Mix Ratio:
Typically 40:1 or 50:1 for high-performance 2-stroke oil (refer to manual for exact specification)
🔧 Transmission
Standard
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-plate clutch
Features
Gear Ratios:
Specific gear ratios detailed within the manual.
Gearbox Oil Type:
SAE 80 or 85W Gear Oil (check manual for exact viscosity and API classification)
Gearbox Oil Capacity:
Approximately 0.8 - 1.0 liters (check manual for exact capacity)
📐 Dimensions
Exterior
Wheelbase:
1475 mm ± 10 mm (approximate, 2003 model)
Weights
Dry Weight:
Approximately 93 kg (205 lbs) (approximate)
🛡️ Safety Features
Ratings
Crash Test Results:
N/A (Competition motocross bike, not typically subjected to road vehicle safety ratings)
Active Features
Braking System:
Hydraulic disc brakes front and rear with braided steel lines.
Passive Features
Frame Construction:
Chromium-molybdenum steel trellis frame for rigidity and impact resistance.
💡 Technology Features
Infotainment
Infotainment System:
N/A (Pure competition motocross bike, no infotainment features)
Driver Assistance
Rider Aids:
N/A (No electronic rider aids)
Connectivity
Connectivity Features:
N/A (No electronic connectivity features)
🔧 Maintenance
Service Intervals
Engine Oil Change:
Every 10-15 hours of riding or as specified in the manual for gearbox oil.
Air Filter Cleaning:
After every few rides or more frequently in dusty conditions.
Spark Plug Inspection:
Every 10-20 hours of riding, replace as needed.
Fluid Specifications
Brake Fluid:
DOT 4 (verify in manual)
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors (verify mixture ratio in manual).
Known Issues
Carburetor Tuning:
Can be sensitive to jetting changes based on altitude, temperature, and exhaust modifications. Manual provides guidance.
Clutch Wear:
Clutch plates can wear over time, especially with aggressive riding. Manual details inspection and replacement.
Suspension Seals:
Fork seals are prone to leaks from impacts; regular inspection and replacement are recommended.
📚 Vehicle History
Brand Heritage
Ktm Motorsport:
KTM has a strong heritage in off-road motorcycle racing, particularly in motocross and enduro, known for performance-oriented machinery.
Model Evolution
Sx Series:
The SX series represents KTM's dedicated motocross line, with the 200 SX offering a potent blend of power and agility for its displacement class.
Production
Manufacturing Location:
Austria (KTM AG)
🏆 Awards & Recognition
Recognitions
Motocross Performance:
KTM motocross bikes are consistently recognized for their performance, handling, and competitive edge in various racing disciplines.
Sale
View full product details →

Unavailable

Sold Out