Category:
Competition Motocross / Off-Road Motorcycle
Target Audience:
Enthusiasts, mechanics, and owners of KTM 200 SXS models requiring in-depth technical information for maintenance and repair.
Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (during its respective production years).
Vehicle Focus:
Lightweight, agile, high-performance two-stroke off-road motorcycle designed for competitive use.
Manual Value:
Official factory documentation provides the most accurate and detailed repair procedures.
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Region Applicability:
Global (factory service manual, content is technical and universally applicable).
Estimated Page Count:
Estimated 300-500+ pages (typical for comprehensive factory service manuals).
Manual Type:
Factory Service Repair Manual
Language:
English (standard for factory manuals unless otherwise specified).
Engine System:
Complete engine disassembly, assembly, tuning, diagnostics, and repair for the 200cc two-stroke engine.
Transmission System:
Gearbox inspection, repair, maintenance, and fluid specifications.
Suspension System:
Front fork (WP Suspension typically) and rear shock absorber servicing, tuning, and rebuild procedures.
Braking System:
Front and rear brake system overhaul, pad replacement, caliper service, and hydraulic system maintenance.
Electrical System:
Wiring diagrams, ignition system troubleshooting, lighting, charging system (if applicable), and component testing.
Chassis And Frame:
Frame inspection, steering head bearing maintenance, and general chassis component servicing.
Fuel System:
Carburetor (likely Keihin PWK or similar) tuning, cleaning, jetting, and fuel tank/line maintenance.
Cooling System:
Radiator and cooling circuit maintenance and inspection (for liquid-cooled models).
Exhaust System:
Expansion chamber and silencer maintenance and inspection.
Routine Maintenance:
Oil changes (gearbox), chain adjustment, air filter cleaning, spark plug replacement, pre-ride checks.
Engine Overhaul:
Top-end rebuild (piston, rings, cylinder), crankshaft and bearing replacement, clutch service.
Suspension Rebuild:
Fork seal replacement, fork oil change, shock absorber service.
Brake Service:
Brake bleeding, pad replacement, rotor inspection.
Troubleshooting:
Diagnostic flowcharts and symptom-based problem solving for common issues.
Wiring Diagrams:
Detailed electrical schematics for all model years covered.
Torque Specifications:
Precise torque values for critical fasteners throughout the motorcycle.
Depth Level:
Comprehensive (covers everything from routine maintenance to complete engine and chassis rebuilds).
Diagnostic Capabilities:
Advanced diagnostic procedures, including electrical testing and component troubleshooting.
Rebuild Procedures:
Detailed step-by-step instructions for complete engine, transmission, and suspension rebuilds.
Searchability:
Likely text-searchable PDF for easy navigation.
Print Quality:
High-resolution, suitable for printing key sections or the entire manual.
Binding Type:
N/A (Digital PDF download).
Paper Type:
N/A (Digital PDF download).
Engine Type:
Liquid-cooled, two-stroke, single-cylinder
Displacement:
193 cc (approximately, based on typical KTM 200cc engines of that era).
Bore X Stroke:
Not explicitly stated in product info, but typically around 64 mm x 60 mm for this displacement.
Induction:
Carburetor (likely Keihin PWK 38mm or similar).
Ignition System:
Digital CDI (Capacitor Discharge Ignition) with variable ignition timing.
Lubrication:
Pre-mix fuel-oil or Autolube system (manual will specify which).
Horsepower:
Estimated 35-40+ HP (highly dependent on year and specific tuning).
Torque:
Not explicitly stated, but strong mid-range and top-end power delivery.
Fuel Type:
Unleaded gasoline (minimum 95 RON).
Carburetor Model:
Likely Keihin PWK 38 AS or similar.
Seat Height:
Approximately 37.6 inches (955 mm) - varies slightly by year.
Ground Clearance:
Approximately 13.8 inches (350 mm) - varies slightly by year.
Dry Weight:
Approximately 210 lbs (95 kg) - varies slightly by year.
Fuel Tank Capacity:
Approximately 8.5 Liters (2.2 US Gallons).
Safety Features:
As a competition off-road motorcycle, dedicated safety ratings (like NHTSA or Euro NCAP) are not applicable. Focus is on rider control and mechanical integrity.
Braking System:
Hydraulic disc brakes front and rear.
Suspension Performance:
WP Suspension components designed for optimal handling and rider feedback.
Frame Construction:
Chromoly steel frame for strength and rigidity.
Infotainment System:
N/A (Pure competition off-road motorcycle, no infotainment features).
Driver Assistance Features:
N/A (No electronic rider aids like ABS or traction control).
Connectivity Features:
N/A (No connectivity features).
Engine Oil Change:
Recommended every 10-15 hours of riding or as per manual (check gearbox oil).
Top End Rebuild:
Varies greatly with usage, but typically 50-100 hours for competitive use.
Air Filter Cleaning:
After every few rides or if heavily soiled.
Gearbox Oil Type:
KTM recommends specific gearbox oils; manual will specify SAE 10W/50 or 10W/40 high-quality motorcycle gear oil.
Coolant Type:
Ethylene glycol-based coolant with anti-corrosion additives, mixed 50/50 with distilled water.
Fork Oil Type:
Specific suspension fluid (e.g., WP Suspension Fluid, SAE 5W or 7.5W depending on application).
Common Wear Items:
Piston rings, clutch plates, wheel bearings, steering head bearings, swingarm bearings, fork seals.
Performance Tuning Tips:
Carburetor jetting adjustments based on altitude and temperature are crucial for optimal performance.
Two Stroke Specific Maintenance:
Regular decarbonization of exhaust port and power valve is necessary.
Brand Origin:
KTM AG, Austria, known for off-road motorcycle racing heritage.
200 Sxs Development:
The SXS models were often 'factory replica' or 'works' editions, featuring higher specifications and performance upgrades over standard SX models.
Production Period:
The 200 SXS model was produced across this 1999-2010 timeframe, with evolutionary updates.
