Category:
High-performance off-road motocross motorcycle.
Target Audience:
Competitive motocross riders, serious off-road enthusiasts, and those performing their own maintenance and repairs.
Segment:
2-stroke 200cc motocross segment, competing with models from Yamaha, Honda, Suzuki, and Kawasaki of similar displacement and purpose.
Performance Focus:
Known for its potent 2-stroke engine performance, lightweight chassis, and agile handling characteristic of KTM's 'Ready to Race' philosophy.
Manual Value Proposition:
Essential tool for owners and technicians to maintain optimal performance, diagnose issues, and execute repairs correctly, preserving the motorcycle's value and longevity.
Applicable Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Geographic Coverage:
Likely covers models sold in primary global markets where KTM distributes the 200 SX. Specific regional variations, if any, are usually detailed.
Model Specific Coverage:
Exclusive to the KTM 200 SX model line.
Estimated Page Count:
Extensive; typically 400-800 pages for a comprehensive factory service manual covering multiple years and systems.
Type:
Factory Service Repair Manual
Purpose:
Provides in-depth guidance for diagnosis, maintenance, repair, and overhaul of the KTM 200 SX.
Language:
English (standard for factory manuals unless otherwise specified)
Engine Mechanical:
Engine assembly, disassembly, cylinder head, piston, crankshaft, connecting rod, balancing, lubrication system, cooling system (if applicable), engine specifications.
Engine Fuel System:
Carburetor (likely Mikuni or Keihin), fuel tank, fuel lines, fuel filter, throttle control, jetting specifications, troubleshooting.
Engine Ignition System:
CDI unit, ignition coil, spark plug, timing specifications, troubleshooting.
Transmission Drivetrain:
Clutch operation and adjustment, gearbox components, gear ratios, shifting mechanism, chain and sprockets, lubrication.
Suspension Front:
Fork disassembly, assembly, oil type and level, seal replacement, spring specifications, damping adjustments.
Suspension Rear:
Shock absorber service, linkage maintenance, bearing checks, spring preload adjustments.
Brakes:
Hydraulic brake system, caliper servicing, master cylinder, brake fluid type and bleeding procedure, pad replacement, rotor specifications.
Wheels Tires:
Wheel bearing maintenance, spoke tensioning, tire pressure specifications, rim types.
Electrical System:
Wiring diagrams, lighting, horn, battery maintenance, fuses, stator output, troubleshooting.
Frame Chassis:
Frame inspection, headstock bearing service, swingarm maintenance, bolt torques.
Bodywork Controls:
Seat, fuel tank cover, fenders, handlebars, levers, cables, footpegs, general assembly.
Preventive Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain lubrication, brake checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon faults, symptom analysis.
Repair Overhaul:
Step-by-step instructions for component disassembly, cleaning, inspection, repair, and reassembly.
Component Replacement:
Detailed guides for replacing wear items and failed components.
Adjustment Calibration:
Procedures for adjusting clutch, brakes, cables, suspension, and engine parameters.
Special Tools:
Identification and usage instructions for specialized tools required for specific tasks.
Depth:
Comprehensive; covers everything from basic rider-level maintenance to full engine and chassis rebuilds.
Diagnostic Capability:
Advanced diagnostic information, including electrical circuit analysis and component testing.
Rebuild Procedures:
Detailed rebuild procedures for major engine and transmission components.
Configuration:
2-stroke, single-cylinder
Displacement:
Approximately 193cc (actual displacement to be confirmed within manual)
Bore X Stroke:
Specific dimensions to be detailed in the manual.
Cooling System:
Liquid-cooled (standard for this class and era of motocross bikes)
Horsepower Estimate:
Likely in the range of 35-40 HP (actual figures in manual)
Torque Estimate:
Specific torque figures to be detailed in the manual.
Carburetor Type:
Likely Mikuni TM series or Keihin PWK series (specific model to be confirmed)
Fuel Type:
Unleaded gasoline, typically 91 octane or higher (check manual for specific recommendations)
Fuel Mixture:
Pre-mix 2-stroke oil and gasoline (ratio specified in manual)
Oil Change:
Regular checks and changes of transmission oil and engine oil (if separate systems) as per manual recommendations, typically every 10-20 hours of riding or annually.
Air Filter Cleaning:
Frequent cleaning or replacement, especially after riding in dusty conditions (interval specified in manual).
Spark Plug Replacement:
Recommended replacement based on hours of use or performance degradation (specific interval in manual).
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment (intervals specified in manual).
Engine Oil:
Manual will specify the exact grade and type of 2-stroke oil and transmission oil (e.g., SAE 80 or specific ATF).
Coolant:
Manual will specify coolant type and mixture ratio if applicable (likely a permanent antifreeze/water mix).
Brake Fluid:
Typically DOT 4 hydraulic brake fluid (confirm exact specification in manual).
Common Wear Items:
Piston rings, clutch plates, fork seals, swingarm bearings, wheel bearings, chain and sprockets are common wear items requiring periodic inspection and replacement.
Potential Trouble Areas:
Carburetor jetting sensitivity to altitude and temperature, 2-stroke engine top-end wear rates (piston/rings), clutch wear are common focus areas for this type of motorcycle.
