🏷️ Basic Information

Make:

KTM

Model:

200 SX

Model Variant:

2-stroke Motocross

Generation Designation:

Early 2000s Generation

Chassis Code:

Likely specific to the 200 SX platform of that era, typically alphanumeric.

👋 Introduction

Market Position:

The KTM 200 SX from 2003-2004 was positioned as a competitive entry-level to mid-tier 2-stroke motocross bike, known for its nimble handling and punchy engine performance, often favored by amateur racers and trail riders looking for an agile off-road machine.

Competitive Analysis:

Competed against similar displacement 2-stroke motocross bikes from Japanese manufacturers like Yamaha (YZ250), Honda (CR250), and Suzuki (RM250), as well as other European brands. KTM's focus on off-road prowess and aggressive styling was a key differentiator.

Key Features:

Lightweight chassis, potent 2-stroke engine, WP suspension components, strong braking system, and KTM's signature orange livery. This manual provides the essential factory data to maintain and repair these features.

📋 Manual Details

Coverage Areas:

Complete official factory service and repair documentation for KTM 200 SX models from 2003 and 2004.

Page Count:

Hundreds of pages (as stated in product description).

Manual Type:

Factory Service Repair Manual

Language:

Likely English (standard for international factory manuals), but could potentially include other languages depending on the original distribution.

Format:

PDF Download

📖 Manual Coverage

Systems Covered:

Engine (top-end, bottom-end, carburetor, ignition, cooling), Transmission, Chassis, Suspension (front and rear), Brakes (front and rear), Electrical System (wiring diagrams, components), Fuel System, Exhaust System, Frame, Wheels, Tires, Controls.

Procedures Included:

Routine maintenance, troubleshooting, diagnostics, complete disassembly and reassembly of all major components, engine rebuild procedures, suspension tuning and repair, brake bleeding and component replacement, carburetor adjustment and overhaul, electrical system diagnosis and repair, torque specifications, special tool requirements, preventative maintenance schedules.

Technical Depth:

Comprehensive factory-level detail, suitable for professional technicians and experienced DIY mechanics. Covers everything from basic fluid changes and adjustments to full engine and transmission overhauls.

📊 Manual Specifications

File Format:

Portable Document Format (PDF)

Print Quality:

Designed for printable output, allowing users to print individual pages or the entire manual. Quality depends on the original source but is typically high resolution for diagrams and text.

Binding Type:

N/A (Digital Download - User dependent for physical binding)

Paper Type:

N/A (Digital Download - User dependent for physical printing)

⚙️ Engine Specifications

Primary Engine:

2-stroke, single-cylinder, liquid-cooled

Bore X Stroke:

Typically around 62.5 mm x 65 mm (verify specific year for exact figures).

Displacement:

193 cc (for 200 SX)

Carburetor Type:

Likely a Keihin PWK series carburetor, typically 36mm or 38mm.

Ignition System:

Digital CDI ignition system.

Cooling System:

Liquid cooling with integrated radiator.

Horsepower Estimate:

Estimated 30-35 HP range at the crank (typical for this displacement and era).

Torque Estimate:

Estimated 20-23 lb-ft range (typical for this displacement and era).

Fuel Type:

Unleaded gasoline, 91-98 octane recommended (pre-mix with 2-stroke oil).

Oil Mixing Ratio:

Typically 50:1 or 40:1 with high-quality 2-stroke synthetic oil (specific ratio in manual).

🔧 Transmission

Transmission Type:

6-speed constant mesh manual gearbox.

Optional Transmission:

N/A (Single transmission configuration for this model).

Clutch Type:

Hydraulically operated, multi-plate wet clutch.

Gear Ratios:

Specific gear ratios will be detailed in the manual (e.g., 1st: 2.133, 2nd: 1.611, 3rd: 1.333, 4th: 1.130, 5th: 1.000, 6th: 0.864 - typical for this era/model).

Final Drive:

Chain drive (typically 520 pitch chain).

📐 Dimensions

Overall Length:

Approx. 2150 mm (verify in manual).

Overall Width:

Approx. 800 mm (verify in manual).

Seat Height:

Approx. 960 mm (verify in manual).

Ground Clearance:

Approx. 350 mm (verify in manual).

Dry Weight:

Approx. 93-95 kg (verify in manual).

Fuel Tank Capacity:

Approx. 8-9 liters (verify in manual).

Wheelbase:

Approx. 1440 mm (verify in manual).

🛡️ Safety Features

Safety Ratings:

Motocross bikes are not typically subjected to the same government safety ratings (e.g., NHTSA, Euro NCAP) as street vehicles. Safety is primarily rider-dependent and related to the bike's handling and braking performance.

Active Features:

Responsive braking system (disc brakes front and rear), agile handling characteristics, strong frame for stability.

Passive Features:

Robust frame construction, durable bodywork, adequate rider controls for off-road operation.

💡 Technology Features

Infotainment System:

N/A (Motocross bike, not equipped with traditional infotainment systems).

Driver Assistance Features:

N/A (Motocross bike, no driver assistance features like ABS or traction control in this era).

Connectivity Options:

N/A (Motocross bike, no connectivity features).

Engine Management System:

Basic electronic ignition control unit (CDI) with pre-programmed ignition maps. No advanced electronic engine management features.

🔧 Maintenance

Service Intervals:

Detailed service intervals for oil changes, filter cleaning/replacement, spark plug checks, chain maintenance, brake checks, suspension service, and engine top-end inspections will be provided in the manual.

Top End Rebuild Interval:

Typically recommended every 40-60 hours of aggressive riding or annually for recreational use, depending on operating conditions and oil quality. Specific hours will be in the manual.

Engine Oil Type:

High-quality 2-stroke synthetic racing oil (e.g., Motorex Cross Power 2T, Castrol Power 1 TTS). Specific viscosity and brand recommendations in the manual.

Transmission Oil Type:

KTM recommends specific transmission oils, often a gear oil like Motorex Gear Oil 10W/40 or equivalent SAE 80W/90 GL-4. Capacity approximately 0.75-0.85 Liters. Verify in manual.

Coolant Type:

Ethylene glycol-based coolant mixed with distilled water (50/50 ratio). Specific antifreeze/coolant recommendations in the manual. Capacity approximately 0.6-0.7 Liters.

Brake Fluid Type:

DOT 4 brake fluid (verify specific specification in manual).

Fork Oil Type:

Specific viscosity fork oil (e.g., WP Suspension Fluid 5W, 7.5W, or 10W) and level specified in the manual. Oil level is critical for performance.

Known Issues:

Common 2-stroke motocross issues can include wear on piston rings and cylinder, clutch wear, carburetor jetting sensitivity to altitude/temperature, and the need for regular chain and sprocket replacement. The manual will guide on diagnosing and addressing these.

Carburetor Jetting Adjustment:

The manual will provide factory jetting specifications and troubleshooting for carburetor performance issues, which are common in 2-strokes.

Suspension Service:

Regular service of WP suspension (seals, bushings, oil) is crucial for maintaining optimal handling and preventing premature wear. Manual details procedures.

📚 Vehicle History

Brand Heritage:

KTM, founded in Austria, has a long and storied history in off-road motorcycle racing, particularly in motocross and enduro. The 'Ready to Race' slogan reflects their commitment to performance and competition.

Model Evolution:

The 200 SX was part of KTM's evolution of their 2-stroke motocross line, offering a middle ground between the 125cc and 250cc classes. It aimed to provide a torquier engine than the 125 without the increased weight or complexity of a 250.

Production Years:

2003 and 2004 model years covered by this manual. The 200 SX platform generally ran through various iterations in the early to mid-2000s.

Manufacturing Location:

Primarily Austria (KTM's home country), though some components or assembly might have occurred elsewhere depending on global distribution.

🏆 Awards & Recognition

Recognitions:

While specific awards for the 2003/2004 200 SX are not readily documented, KTM consistently receives accolades and high ratings in motocross and off-road publications for its performance, handling, and build quality across its model range.

Magazine Ratings:

Contemporary reviews and comparisons from motocross magazines of the era would provide performance ratings and feedback. This manual is the definitive factory source for technical specifications that underpinned any positive reviews.

Certifications:

N/A (Production vehicle certifications not applicable to this type of competition off-road machine.)