Segment:
Performance Motocross / Off-Road Competition
Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (during the specified model years).
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.
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.
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.
Type:
Workshop Service Manual
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.
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.
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.
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)
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.
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.
Piston Type:
Typically a single-ring, performance-oriented piston.
Type:
6-speed manual transmission
Clutch:
Hydraulically actuated, multi-plate wet clutch
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.
Wheelbase:
Varies slightly by year, generally around 1440-1470 mm.
Dry Weight:
Around 95-100 kg, depending on specific model and equipment.
Fuel Tank Capacity:
Typically 7-9 liters.
Front Travel:
Approximately 280-300 mm (WP USD forks).
Rear Travel:
Approximately 300-330 mm (WP PDS or linkage-driven mono-shock).
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.
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.
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.
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.
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.
Manufacturing Location:
Austria (KTM headquarters and primary manufacturing)
