🏷️ Basic Information

Make:

KTM

Model:

200 SX

Product Type:

Factory Service Repair Manual

Engine Code Identifier:

Likely a variant of KTM's 2-stroke single-cylinder, often designated by a '200' prefix, specific code not provided but implied by model name.

Chassis Code Identifier:

Specific chassis code not provided, but typical for SX models would be within KTM's established motocross chassis designations.

👋 Introduction

Category:

Motocross Competition Motorcycle

Target Segment:

Entry-level to intermediate motocross riders, focusing on a balance of performance and manageability.

Key Competitors:

Yamaha YZ125, Honda CR125R (historical comparison as engine size is slightly different), Husqvarna TC125, GasGas MC125.

Engine Type:

Lightweight, high-revving 2-stroke engine, known for its tractable power delivery.

Chassis Design:

Aggressive and agile chassis, optimized for motocross track performance.

Suspension Quality:

Typically features WP (White Power) suspension components, renowned for their quality and adjustability.

Braking Performance:

Utilizes high-performance Brembo braking components.

Ergonomics:

Designed for optimal rider control and comfort during intense racing conditions.

📋 Manual Details

Coverage Scope:

Comprehensive repair and maintenance for the KTM 200 SX.

Target Audience:

Mechanics and DIY enthusiasts.

Estimated Page Count:

Typically 300-600 pages for a comprehensive factory service manual, exact count not specified.

Type:

Factory Service Repair Manual

Language:

English (common for factory manuals, specific language not explicitly stated but implied by product description).

Format:

PDF Download

📖 Manual Coverage

Engine Mechanical:

Complete engine disassembly, assembly, inspection, and overhaul procedures for the 2-stroke engine.

Fuel System:

Carburetor tuning, disassembly, cleaning, and adjustment; fuel tank, petcock, and fuel line maintenance.

Ignition System:

Ignition coil testing, stator and rotor inspection, spark plug specifications, and troubleshooting.

Cooling System:

Radiator, hoses, water pump inspection, coolant type and capacity, bleeding procedures (if liquid-cooled variant).

Exhaust System:

Exhaust pipe and silencer inspection, maintenance, and potential performance modifications.

Transmission:

Clutch operation, disassembly, adjustment, and replacement; gearbox inspection and lubrication.

Drivetrain:

Chain and sprocket inspection, adjustment, and replacement; rear hub and bearing maintenance.

Suspension Front:

Fork disassembly, seal replacement, oil level and type specifications, spring inspection, and adjustment procedures.

Suspension Rear:

Shock absorber inspection, seal replacement, oil and gas pressure specifications, linkage maintenance, and bearing inspection.

Brakes Front:

Brake caliper inspection, pad replacement, fluid type and bleeding procedures, master cylinder maintenance, and rotor specifications.

Brakes Rear:

Brake caliper inspection, pad replacement, fluid type and bleeding procedures, master cylinder maintenance, and rotor specifications.

Wheels And Tires:

Wheel bearing inspection and replacement, spoke tension adjustment, tire pressure recommendations, and wheel mounting.

Electrical System:

Wiring diagram, battery maintenance, lighting system, fuse replacement, and basic troubleshooting.

Frame And Bodywork:

Frame inspection, subframe maintenance, plastic component removal and installation, and seat maintenance.

Routine Maintenance:

Oil changes, filter replacements, chain adjustments, bolt torquing, and general inspection.

Troubleshooting Guides:

Diagnostic procedures for common starting, running, and performance issues.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly and reassembly, including piston, ring, and crankshaft service.

Suspension Overhaul:

Detailed instructions for rebuilding front forks and rear shock absorbers.

Brake System Service:

Brake bleeding, pad and rotor replacement, and caliper service.

Clutch Adjustment And Replacement:

Procedures for maintaining clutch engagement and replacing clutch components.

Electrical Diagnostics:

Guidance on identifying and resolving electrical faults using wiring diagrams.

Depth:

Factory-level technical detail, suitable for comprehensive repairs and diagnostics.

Diagnostic Tools:

Mentions of specific tools and measurements required for accurate diagnosis and repair.

Torque Specifications:

Includes critical torque values for all fasteners.

Clearances And Tolerances:

Provides essential engine and component clearances for proper assembly and function.

📊 Manual Specifications

Format:

PDF

Searchable:

Typically PDF manuals are searchable, facilitating quick information retrieval.

Quality:

High-resolution, suitable for printing specific sections or the entire manual.

Type:

N/A (Digital PDF format)

Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Configuration:

Single-cylinder, 2-stroke

Displacement:

196cc (approximately, specific bore/stroke for 200 SX would need exact model year verification, but '200' indicates this range).

Bore X Stroke:

Specific values depend on model year, but typical for this class is around 64mm x 62.1mm.

Cooling System:

Liquid-cooled (standard for modern SX models)

Induction:

Reed valve induction

Ignition:

Digital CDI (Capacitive Discharge Ignition)

Horsepower:

Approx. 35-40 HP (estimated, exact figures vary by year and tuning).

Torque:

Specific torque figures are often not as emphasized as peak horsepower in this class, but significant mid-range power is expected.

Carburetor Type:

Keihin PWK (typically 38mm or similar).

Fuel Type:

Unleaded gasoline, 95-98 RON (research octane number recommended).

Oil Mixture:

Pre-mix 2-stroke engine oil, typically a 50:1 or 60:1 ratio with gasoline (refer to manual for exact ratio).

🔧 Transmission

Type:

6-speed manual transmission

Clutch:

Wet multi-plate clutch

Final Drive:

Chain drive (520 pitch chain typically)

Gear Ratios:

Specific ratios vary by model year, but designed for aggressive motocross performance.

📐 Dimensions

Wheelbase:

Typically around 1440-1450 mm (56.7-57.1 inches).

Ground Clearance:

Approximately 350-360 mm (13.8-14.2 inches).

Seat Height:

Around 960-970 mm (37.8-38.2 inches).

Dry Weight:

Typically in the range of 90-95 kg (198-209 lbs) without fluids.

Fuel Tank Capacity:

Approximately 7-8 liters (1.8-2.1 gallons).

🛡️ Safety Features

Crash Test Ratings:

N/A (Off-road competition vehicles are not subject to standard road vehicle crash testing regulations).

Braking System:

Hydraulic disc brakes front and rear for powerful stopping capability.

Chassis Integrity:

Strong, lightweight chromoly steel frame designed for impact resistance.

Handlebar Design:

Fat bar handlebars with handguards for rider protection and control.

💡 Technology Features

Features:

N/A (This is a competition motocross bike, no infotainment systems are present).

Features:

N/A (Competition dirt bikes are designed for manual rider input and do not feature electronic driver assistance systems).

Features:

N/A

🔧 Maintenance

Oil Change:

Engine oil/transmission oil change every 15-20 operating hours (or as specified in the manual).

Air Filter Cleaning:

Clean air filter after every few rides or as conditions dictate (critical for 2-strokes).

Chain Lubrication And Adjustment:

Lubricate chain every 5-10 operating hours; adjust tension as needed.

Spark Plug Replacement:

Inspect spark plug regularly; replacement interval depends on usage and plug type (e.g., every 20-30 hours).

Top End Rebuild:

Piston and ring inspection/replacement typically every 50-100 operating hours, depending on riding style and maintenance.

Engine Oil:

High-quality 2-stroke pre-mix oil (e.g., Motorex Cross Power 2T, Bel-Ray Si-7).

Transmission Oil:

KTM recommends specific gear oils like Motorex Gear Oil 10W/40 or 15W/50 (refer to manual for exact spec).

Coolant:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0).

Brake Fluid:

DOT 4 or DOT 5.1 brake fluid (verify specific requirement for Brembo systems).

2 Stroke Maintenance:

2-stroke engines require diligent maintenance, including correct fuel/oil mixture and regular top-end service, to prevent premature wear.

Clutch Wear:

Clutch plates can wear faster under aggressive riding; proper adjustment and timely replacement are crucial.

Suspension Seals:

Fork and shock seals can be prone to wear and leaks, especially in dusty off-road environments.

📚 Vehicle History

Origin:

KTM AG, an Austrian manufacturer renowned for its off-road motorcycles.

Sx Lineage:

The SX (Motocross) line represents KTM's core competition dirt bike offerings, with models evolving to incorporate advancements in engine technology, suspension, and chassis design.

200Cc Class:

KTM has a history of producing successful 2-stroke models in various displacements, including the 125cc and 250cc classes, with the 200cc offering a niche for riders seeking more torque than a 125 but less aggressive power than a 250.

Manufacturing Location:

Primary manufacturing typically in Austria, with potential for global production sites.

🏆 Awards & Recognition

Motocross Performance:

KTM's SX models consistently receive praise in motocross media for their performance, handling, and competitive edge. Specific awards for the 200 SX would depend on its market introduction and competitive landscape during its production years.