Category:
Off-road competition motorcycle (Motocross/Enduro focus)
Target Audience:
Motocross and off-road riders, mechanics, service technicians, and KTM enthusiasts who perform their own maintenance and repairs.
Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250
Vehicle Focus:
Lightweight, agile, high-performance 2-stroke off-road machine.
Manual Value:
Essential for maintaining the performance and longevity of the KTM 200 SXS, particularly for owners performing their own work.
Geographic Coverage:
Global, reflecting KTM's international presence. Specific regional variations are unlikely for this model.
Estimated Pages:
Estimated 300-500 pages, typical for a comprehensive workshop manual of this era.
Type:
Service Repair Workshop Manual
Language:
English (primary). May include translations for major markets, but English is standard for technical documentation.
Powertrain:
Engine overhaul, carburetor tuning, ignition system, exhaust system, cooling system (if applicable to specific 200 SXS variants).
Chassis:
Frame inspection and repair, suspension (front forks, rear shock absorber), steering system, wheel bearings.
Brakes:
Front and rear brake system inspection, hydraulic fluid replacement, caliper maintenance, pad replacement, bleeding procedure.
Electrical:
Wiring diagrams, lighting system, ignition system components, battery maintenance, troubleshooting of electrical faults.
Bodywork:
Plastics removal and installation, seat, fuel tank, and subframe components.
Maintenance:
Scheduled maintenance tasks, oil changes, air filter cleaning/replacement, spark plug replacement, chain and sprocket maintenance.
Repair:
Detailed step-by-step instructions for component removal, repair, and reinstallation for all covered systems.
Troubleshooting:
Diagnostic charts and symptom-based troubleshooting guides for common mechanical and electrical issues.
Specifications:
Torque specifications for all fasteners, critical component clearances, fluid capacities and types.
Depth:
Comprehensive. Covers everything from basic routine maintenance to complete engine and gearbox rebuilds, electrical system diagnostics, and suspension overhauls.
Searchability:
Likely text-searchable PDF, allowing for quick information retrieval.
Printability:
Designed for printing, with clear diagrams and text. Quality depends on the source PDF.
Binding:
N/A (Digital PDF Download)
Paper Quality:
N/A (Digital PDF Download)
Type:
2-stroke, single-cylinder
Displacement:
Approximately 193-200 cc (exact displacement may vary slightly by year or specific SXS variant)
Bore X Stroke:
Specific figures would be detailed in the manual, typically around 64mm x 60mm for a 200cc 2-stroke.
Cooling System:
Liquid-cooled
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Horsepower:
Typically in the range of 35-40+ HP (depending on year and specific tuning)
Torque:
Specific figures would be detailed in the manual, usually around 20-25 lb-ft.
Carburetor:
Keihin PWK 38mm (or similar high-performance carburetor, specified in manual)
Fuel Type:
Unleaded gasoline, typically 95 RON or higher (check manual for specific octane requirements and oil mixture ratio for 2-stroke oil).
Premix Ratio:
Typically 1:40 or 1:50 (engine oil to gasoline ratio), specified in manual.
Type:
6-speed manual transmission
Clutch:
Wet multi-plate clutch
Gear Ratios:
Specific ratios would be detailed in the manual. Designed for strong low-end and mid-range power delivery for off-road use.
Transmission Oil:
Specific type and capacity (e.g., SAE 75W/80W or SAE 10W/30 GL-4, manual will specify exact type and quantity).
Wheelbase:
Approximately 1450-1470 mm (57.1-57.9 inches), varies slightly by year.
Seat Height:
Approximately 900-950 mm (35.4-37.4 inches), adjustable via suspension settings.
Dry Weight:
Approximately 95-105 kg (209-231 lbs), depending on year and specific SXS equipment.
Fuel Tank Capacity:
Approximately 7-9 liters (1.8-2.4 US gallons).
Oil Capacity:
Transmission oil capacity specified in manual, typically under 1 liter.
Crash Safety:
N/A (Motorcycle, not subject to automotive crash safety ratings).
Braking System:
Hydraulic disc brakes, front and rear. Brembo components often used.
Suspension:
High-performance WP suspension (forks and shock), adjustable for damping and preload.
Lighting:
Headlight and taillight for visibility; legality depends on local regulations for street use.
Oil Change:
Engine oil/premix: Check and top-up as needed. Transmission oil: Every 15-20 hours of riding or annually.
Air Filter:
Clean/inspect every 5-10 hours of riding, depending on conditions.
Spark Plug:
Inspect/replace every 20-30 hours of riding. Specific plug type (e.g., NGK BR8EG) will be in manual.
Piston Ring Inspection:
Recommended every 40-60 hours for competitive use; more extended for recreational riders.
Cooling System Coolant:
Mixture of distilled water and anti-freeze (e.g., ethylene glycol based), specified by KTM, typically 50/50 mix.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Clutch plates, piston rings, spark plugs, wheel bearings, chain and sprockets, fork seals due to demanding off-road use.
Potential Failures:
Overheating if cooling system is neglected, carburetor jetting issues due to altitude/temperature changes, kickstart mechanism wear.
Heritage:
KTM AG is an Austrian manufacturer renowned for its off-road motorcycles, with a strong racing pedigree in Motocross, Enduro, and Dakar Rally.
Development Focus:
The 200 SXS was developed as a competitive 200cc class motocross machine, offering a potent blend of power and handling for its displacement.
Manufacturing Origin:
Austria
Series Continuity:
The 200 SXS was part of KTM's SX (Motocross) and EXC (Enduro) lineage, with the 200cc engine offering a distinct niche.
Motorcycle Awards:
While specific awards for the 200 SXS model are not widely documented as distinct entities, KTM models of this era consistently performed well in magazine shootouts and received praise for their performance and handling in the motocross and enduro disciplines.
Customer Satisfaction:
Generally high among KTM owners who value performance and handling. The 200 SXS was praised for its potent engine character.
Emissions:
Designed for off-road competition use, typically not street-legal or certified for road emissions standards without modification.
