Model Variant:
2-Stroke Motocross
Production Years Covered:
1999, 2000, 2001, 2002, 2003
Chassis Code:
Not explicitly stated, typical for off-road bikes of this era.
Engine Code:
Not explicitly stated, but refers to the specific 200cc 2-stroke engine.
Motorcycle Segment:
Entry-level to intermediate motocross/off-road competition.
Target Audience:
Amateur racers, recreational riders, mechanics specializing in off-road motorcycles.
Competitors:
Yamaha YZ250, Suzuki RM250, Honda CR250R, Kawasaki KX250 (though often categorized slightly differently due to displacement).
Performance Focus:
Agile handling, potent 2-stroke power delivery, competitive pricing for its class.
Brand Philosophy:
KTM's 'Ready to Race' ethos emphasizes performance and off-road capability.
Engine:
Complete engine overhaul, top-end and bottom-end procedures, carburetor tuning, cooling system, ignition system, exhaust system.
Transmission:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear shift mechanism, lubrication.
Chassis:
Frame inspection and repair, suspension (forks and rear shock) overhaul and adjustments, wheel bearing replacement, steering head bearing service.
Brakes:
Hydraulic brake system maintenance, caliper service, master cylinder overhaul, fluid replacement, pad replacement.
Electrical:
Wiring diagrams, lighting system, ignition system components, troubleshooting electrical faults, battery maintenance.
Bodywork And Plastics:
Fairing removal and installation, seat maintenance, fuel tank, fender service.
Maintenance:
Routine servicing, oil changes, filter replacements, chain adjustment, spark plug service, pre-ride inspections.
Troubleshooting:
Diagnostic procedures for common issues, electrical fault finding, engine performance problems.
Repair:
Component-level repair and replacement, engine rebuilds, suspension servicing, brake system overhauls.
Disassembly And Assembly:
Step-by-step instructions for removing and refitting major assemblies and components.
Specifications And Measurements:
Torque values, clearances, tolerances, diagnostic readings.
Depth:
Comprehensive; suitable for qualified mechanics and experienced DIY enthusiasts. Covers detailed diagnostic and repair procedures beyond basic owner's manual information.
Configuration:
Single-cylinder, 2-stroke
Displacement:
194 cc (approx.)
Bore X Stroke:
Typically around 62.5 mm x 65 mm (specific to the 200 SX model).
Cooling System:
Liquid-cooled
Ignition System:
Electronic CDI (Capacitor Discharge Ignition)
Horsepower:
Estimated 35-40 HP at peak (varies with tuning and specific year).
Torque:
Specific figures not readily available, but known for strong mid-range power.
Carburetor:
Mikuni TM Series (e.g., TM38) or Keihin PWK, depending on exact model year.
Fuel Type:
Unleaded gasoline (minimum 95 octane recommended), mixed with 2-stroke oil (e.g., 1:30 to 1:50 ratio).
Premix Ratio:
Refer to manual for precise recommendations; typically 1:40.
Wheelbase:
Approximately 1450 mm (57.1 inches).
Seat Height:
Approximately 960 mm (37.8 inches).
Ground Clearance:
Approximately 360 mm (14.2 inches).
Dry Weight:
Approximately 95 kg (209 lbs).
Fuel Tank Capacity:
Approximately 8 liters (2.1 US gallons).
Crash Test Results:
N/A for off-road motorcycles.
Brakes:
Hydraulic disc brakes front and rear.
Suspension:
WP suspension (often USD forks and monoshock rear) designed for off-road control and impact absorption.
Frame Construction:
Steel perimeter frame designed for strength and rigidity.
Handguards:
Standard on many models for rider protection.
System:
N/A (Competition Off-Road Motorcycle)
Features:
N/A (Competition Off-Road Motorcycle)
Features:
N/A (Competition Off-Road Motorcycle)
System:
Basic CDI ignition system, carburetor-controlled fuel delivery.
Oil Change:
Refer to manual; typically every 10-15 hours of riding for engine oil (if applicable, or gearbox oil).
Air Filter Cleaning:
After every few rides or as needed based on conditions; critical for 2-stroke engine longevity.
Spark Plug Check:
Regularly, or every 10-20 hours of riding.
Top End Rebuild:
Depends heavily on usage; typically 50-100 hours for competitive use, longer for recreational.
Engine Oil Type:
High-quality 2-stroke premix oil (specific brand recommendations may be in manual).
Gearbox Oil Type:
SAE 10W/40 or 10W/50 motorcycle gear oil (e.g., Motorex, Bel-Ray).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, piston rings, spark plugs, air filters, chain and sprockets, wheel bearings, swingarm/linkage bearings.
Engine Characteristics:
2-stroke engines require diligent maintenance of the top end for optimal performance and longevity. Carburetor tuning can be sensitive to altitude and temperature.
Suspension Maintenance:
Regular servicing of forks and rear shock is crucial for maintaining optimal damping and preventing seal leaks.
Company Origin:
Founded in Austria in 1934.
Motorcycle Focus:
Strong heritage in off-road racing, including motocross, enduro, and rally.
200 Sx Lineage:
The 200 SX was positioned as a more potent and competitive option within the smaller displacement motocross class, offering a blend of 125cc agility with 250cc-like power.
Development Period:
This era (late 90s/early 2000s) saw significant development in motocross technology, with advancements in suspension, chassis design, and engine tuning.
Manufacturing Location:
Austria (typically for KTMs of this period).
