Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Chassis Code:
Not specified in product data, typically model-specific designations for off-road motorcycles.
Engine Code:
Not specified in product data, typically model-specific designations for off-road motorcycles.
Motorcycle Segment:
Motocross/Off-Road Competition
Target User:
Motocross racers, off-road enthusiasts, mechanics, and DIY repair technicians working on KTM 200 SX/SXS models.
Brand Strength:
KTM is renowned for its performance-oriented off-road motorcycles, often referred to as 'Ready to Race.'
Model Competitors:
Competes against other 2-stroke motocross bikes of similar displacement from brands like Yamaha (YZ250), Honda (CR250), Suzuki (RM250), and Kawasaki (KX250) from the same era.
Performance Focus:
Designed for aggressive off-road riding, emphasizing power delivery, handling, and suspension performance.
Manual Utility:
Provides the essential technical information required to maintain, diagnose, and repair the KTM 200 SX/SXS, ensuring optimal performance and longevity.
Engine Mechanical:
Complete overhaul procedures, piston and ring replacement, cylinder head service, valve adjustment (if applicable, though likely a 2-stroke), crankshaft and connecting rod service, lubrication system.
Engine Fuel System:
Carburetor disassembly, cleaning, adjustment, and tuning. Fuel tank, fuel lines, and fuel filter service. Ignition system (spark plug, coil, CDI unit diagnosis and replacement).
Transmission Drivetrain:
Clutch inspection, adjustment, and replacement. Gearbox disassembly and assembly, gear inspection, shifting mechanism service. Chain and sprockets maintenance and replacement.
Suspension Steering:
Front fork (WP USD forks) service, seal replacement, oil changes, and internal component inspection. Rear shock absorber service and adjustments. Steering head bearing service. Swingarm and linkage bearing maintenance.
Brakes:
Hydraulic brake system service for front and rear. Caliper disassembly, piston inspection, seal replacement. Master cylinder service. Brake fluid bleeding procedures. Pad inspection and replacement. Rotor inspection.
Electrical System:
Wiring diagram analysis, troubleshooting common electrical faults. Lighting system (if applicable), horn, battery maintenance. CDI ignition system diagnostics.
Cooling System:
Radiator inspection and cleaning. Coolant type and replacement. Water pump service (if applicable to the specific 200cc variant). Hose inspection and replacement.
Exhaust System:
Exhaust pipe inspection, packing replacement for silencers (mufflers), and proper assembly.
Bodywork Chassis:
Frame inspection for damage. Seat removal and installation. Fuel tank removal and installation. Plastics and fender maintenance. Footpeg and control lever service.
Routine Maintenance:
Pre-ride checks, oil changes (transmission oil), chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, brake system checks, tire pressure checks.
Troubleshooting:
Diagnostic charts for common running issues, starting problems, electrical faults, and performance complaints. Specific steps to identify root causes.
Engine Rebuild:
Step-by-step instructions for complete engine disassembly, component inspection (e.g., bore condition, piston ring gap), reassembly, and torque specifications.
Suspension Rebuild:
Detailed guide on disassembling and reassembling front forks and rear shock absorbers, including oil levels, type, and damping adjustments.
Carburetor Tuning:
Procedures for adjusting jetting, idle speed, and mixture for optimal performance in various conditions.
Clutch Adjustment:
Correct procedures for adjusting clutch lever free play and ensuring proper engagement/disengagement.
Brake Bleeding:
Step-by-step guide for safely bleeding air from the hydraulic brake systems.
Wheel Bearing Service:
Inspection, cleaning, lubrication, and replacement of wheel bearings.
Steering Head Service:
Inspection and adjustment/replacement of steering head bearings.
Diagnostic Capability:
Advanced diagnostic procedures for engine performance, electrical systems, and suspension tuning.
Repair Scope:
Comprehensive repair information covering everything from routine maintenance to full engine and component overhauls.
Specifications Detail:
Includes detailed torque specifications, clearances, fluid capacities, and technical data required for accurate repairs and adjustments.
Engine Type:
2-Stroke, Single-Cylinder, Liquid-Cooled (typical for this model era)
Displacement:
Approximately 193-200cc (specific designation varies by sub-model and year)
Bore X Stroke:
Specific figures vary, but commonly around 63 mm x 64 mm for similar KTM 200cc 2-strokes.
Power Delivery:
Known for strong mid-range and top-end power characteristic of KTM 2-stroke engines.
Horsepower:
Typically in the range of 35-40+ HP, depending on specific year and tuning.
Torque:
Strong torque output, especially in the mid-range for acceleration out of corners.
Carburetor Type:
High-performance carburetor, often Keihin PWK or similar (e.g., 36mm or 38mm).
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil mixture (pre-mix or Autolube system, typically pre-mix for SX models).
Oil Type:
High-quality 2-stroke synthetic or semi-synthetic engine oil (specific recommendations in manual).
Transmission Type:
6-speed constant mesh sequential manual transmission.
Optional Gear Ratios:
Not typically offered as an option on SX models; gear ratios are model-specific.
Clutch Type:
Hydraulically actuated multi-plate wet clutch.
Final Drive:
Chain drive (e.g., 520 pitch chain).
Transmission Oil Capacity:
Approx. 0.75 - 1.0 liter (refer to manual for exact specification).
Transmission Oil Type:
Dedicated transmission oil (e.g., SAE 10W/40, high-quality motorcycle gear oil) - specific type in manual.
Oil Change Interval:
Every 15-20 hours of riding or annually, whichever comes first (refer to manual for precise interval based on usage).
Air Filter Cleaning:
After every few rides, especially in dusty conditions.
Spark Plug Inspection:
Regularly, typically every 10-15 hours of riding.
Chain Lubrication:
After every ride or every few hours of riding, depending on conditions.
Engine Oil Grade:
Refer to manual for specific 2-stroke oil recommendation (e.g., Motorex, Castrol Power RS).
Transmission Oil Grade:
Refer to manual for specific transmission oil recommendation (e.g., SAE 10W/40 motorcycle gear oil).
Coolant Type:
Ethylene glycol-based antifreeze/coolant mixture with corrosion inhibitors (typically 50/50 mix).
Brake Fluid Type:
DOT 4 or DOT 5.1 hydraulic brake fluid.
Common Wear Items:
Piston rings, clutch plates, wheel bearings, suspension seals, and exhaust packing are common wear items requiring periodic replacement.
Carburetor Jetting:
Can require re-jetting based on altitude, temperature, and modifications for optimal performance.
Power Valve Maintenance:
The power valve mechanism (if present) may require cleaning and maintenance to ensure proper operation.
