Segment:
Performance-oriented off-road motorcycles (Enduro/Motocross).
Competitors:
Yamaha WR250F, Honda CRF250X, Husqvarna TE250, Beta RR 250.
Vehicle Focus:
Lightweight, agile, powerful 2-stroke engine, premium components, off-road capability.
Primary Coverage:
Comprehensive service and repair for KTM 200 SX and 200 EXC models.
Type:
Service Repair Manual
Additional Info:
Includes detailed schematics, torque specifications, and step-by-step repair instructions.
Format:
Digital (PDF), potentially printable
Engine:
Top-end (cylinder, piston, rings), bottom-end (crankshaft, bearings), cooling system, lubrication system, fuel system (carburetor, fuel delivery), ignition system.
Transmission:
Clutch system, gearbox (gear selection, shifting mechanisms), final drive (chain, sprockets).
Chassis:
Frame inspection, suspension (forks, rear shock absorber), steering, wheels, tires, brakes (front and rear).
Electrical:
Wiring diagrams, lighting system, battery, charging system, ignition switch, starter system.
Bodywork:
Plastics, seat, handlebars, fuel tank replacement and fitting.
Maintenance:
Routine checks, oil changes, filter replacements, chain adjustment, spark plug service, valve clearance adjustment (if applicable).
Repair:
Engine disassembly and reassembly, transmission overhaul, suspension servicing, brake caliper rebuild, carburetor tuning and repair.
Troubleshooting:
Diagnostic procedures for common starting issues, running problems, electrical faults, and mechanical failures.
Electrical Diagnostics:
Detailed troubleshooting charts and procedures for electrical system faults.
Suspension Tuning:
Basic adjustments for damping and preload.
Depth:
Comprehensive, covering routine maintenance to complete engine and transmission rebuilds with detailed diagrams and specifications.
Scope:
Factory-level technical information, designed for qualified technicians and knowledgeable enthusiasts.
Type:
2-stroke single-cylinder, liquid-cooled
Displacement:
193 cc (approx.)
Bore X Stroke:
62.5 mm x 65 mm (typical)
Carburetor:
Keihin PWK 38 AS (common)
Ignition:
Digital CDI with adjustable ignition timing
Starting System:
Kick starter
Cylinder Head:
Single overhead camshaft (SOHC) - *Correction: 2-stroke engines typically do not have camshafts in the traditional sense; this refers to the port timing and power valve actuation.*
Power Valve:
KTM's patented PDS (Power, Drive, Suspension) or similar mechanical power valve system.
Horsepower:
Estimated 40-45 HP (varies by tuning and model year)
Torque:
Estimated 25-30 Nm (varies)
Fuel Type:
Unleaded gasoline (95 RON recommended), premixed with 2-stroke oil
Oil Type:
High-quality 2-stroke synthetic oil
Oil Change Engine:
Every 10-15 hours of riding (or annually), check transmission oil level frequently.
Air Filter Cleaning:
After every few rides, especially in dusty conditions.
Spark Plug Check:
Every 20-30 hours of riding.
Chain And Sprocket Inspection:
Regularly, adjust tension as needed.
Fork Seal Inspection:
Regularly, replace as needed.
Engine Oil:
KTM recommends specific 2-stroke oil, or equivalent high-quality synthetic 2-stroke racing oil.
Transmission Oil:
KTM recommends specific gear oil, or equivalent SAE 10W/30 or 10W/40 API SG or higher.
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors (50% mixture with distilled water).
Hydraulic Clutch Fluid:
Mineral oil or specific KTM clutch fluid.
Carburetor Tuning:
Can be sensitive to altitude and temperature, requiring occasional re-jetting.
Clutch Wear:
Heavy use can lead to accelerated clutch plate wear.
Power Valve Maintenance:
The power valve mechanism requires regular cleaning and inspection to ensure proper operation.
Cooling System Efficiency:
Regular flushing and ensuring proper coolant level is crucial for preventing overheating.
