Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Engine Codes:
Specific engine codes vary by year and sub-model; refer to manual for precise identification. Typically 2-stroke single-cylinder.
Segment:
Motocross (MX) / Off-road Competition
Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (during relevant model years).
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.
Utility:
Essential for owners and mechanics to maintain peak performance, diagnose issues, and perform repairs on the KTM 200 SX.
Primary Coverage:
Service, Repair, Workshop
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.
Type:
Service/Repair/Workshop Manual
Language:
Likely English, common for international service manuals. Specific language to be confirmed by seller.
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.
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.
Depth:
Comprehensive. Designed for both routine maintenance and in-depth mechanical repairs and diagnostics, suitable for both amateur and professional mechanics.
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:
Not applicable for PDF download.
Paper Quality:
Not applicable for PDF download. Digital format.
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
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.
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.
Type:
6-speed manual transmission
Gear Ratios:
Specific ratios will be detailed in the manual for each gear.
Clutch:
Hydraulic-actuated, multi-plate wet clutch.
Final Drive:
Chain drive. Manual will cover chain tension adjustment and lubrication intervals.
Transmission Oil Type:
Specific KTM-recommended transmission oil or suitable high-quality gearbox oil (e.g., SAE 80W/90). Manual will confirm.
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.
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.
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.
Crash Test Results:
Not applicable to competition dirt bikes. Safety is focused on rider protection through design and rider skill.
Braking System:
High-performance hydraulic disc brakes front and rear for effective stopping power. Manual details caliper and rotor specifications.
Frame Construction:
Chromoly steel trellis frame, designed for rigidity and impact resistance.
Ergonomics:
Designed for rider control and balance in aggressive off-road riding.
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.
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.
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.
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.
Origins:
KTM, founded in Austria, has a strong legacy in off-road motorcycle racing, particularly motocross and enduro.
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.
Manufacturing Location:
Primarily Austria.
