Market Segment:
Performance Motocross Competition Motorcycle
Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (during their respective production years).
Unique Selling Points:
KTM's renowned handling, potent two-stroke engine performance, and competitive pricing in the 200cc motocross class during its era. SXS variants often featured performance upgrades.
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Manual Type:
Workshop Service Manual
Language:
English (presumed, standard for KTM workshop manuals of this era)
Engine Systems:
Top-end rebuild (piston, rings, cylinder, head), bottom-end rebuild (crankshaft, connecting rod, bearings), carburetor tuning and overhaul, ignition system, cooling system (if applicable to specific 200 SXS variants, though typically air-cooled), exhaust system.
Transmission Drivetrain:
Clutch operation and replacement, gear shifting mechanism, gearbox disassembly and reassembly, final drive chain adjustment and maintenance.
Chassis Suspension:
Front fork (WP Suspension typically) maintenance, seal replacement, oil changes, adjustment procedures. Rear shock absorber (WP Suspension typically) service, rebuild, and adjustment. Frame inspection and repair. Swingarm and linkage maintenance.
Brakes:
Front and rear brake caliper overhaul, pad replacement, fluid bleeding, master cylinder service. Brake disc inspection.
Electrical System:
Wiring diagrams, ignition coil testing, stator and stator coil inspection, troubleshooting common electrical faults, lighting systems (if applicable).
Bodywork Plastics:
Removal and installation of body panels, seat, fuel tank, fenders, and graphics.
Maintenance Procedures:
Regular service tasks: oil changes, filter replacements (air and oil, if applicable), spark plug replacement, chain lubrication and adjustment, general inspection and tightening of fasteners.
Repair Procedures:
Detailed step-by-step instructions for engine, transmission, suspension, brake, and electrical system repairs. Includes engine disassembly, component replacement, and reassembly guidelines.
Troubleshooting Guides:
Diagnostic procedures for common issues, including engine starting problems, power loss, suspension inconsistencies, and electrical faults. Symptom-based troubleshooting trees.
Technical Specifications:
Torque specifications for all critical fasteners, engine tuning parameters, suspension settings, fluid capacities, and recommended service intervals.
Depth Of Coverage:
Comprehensive, from basic rider maintenance to complete engine and suspension rebuilds. Suitable for both home mechanics and professional technicians.
Engine Type:
2-stroke, single-cylinder
Displacement:
Approximately 194cc (exact specification varies slightly by year and specific SXS tune)
Bore X Stroke:
Refer to specific model year in manual for precise dimensions (e.g., ~62.5 mm x 65 mm)
Cooling System:
Liquid-cooled (most likely for SXS variants, check manual for confirmation)
Ignition:
Digital CDI ignition system
Horsepower:
Estimated 35-40+ HP (dependent on specific model year and SXS tuning)
Torque:
Estimated 20-25+ Nm (dependent on specific model year and SXS tuning)
Carburetor:
Keihin PJ or PWK series, typically 36mm (specific model dependent)
Fuel Type:
Unleaded gasoline (95 RON or higher recommended)
Fuel Mixture:
Pre-mix (two-stroke oil mixed with gasoline) - consult manual for specific ratio (e.g., 32:1 or 40:1).
Transmission Type:
6-speed manual
Optional Features:
N/A (Standard motocross configuration)
Clutch Type:
Hydraulically operated, multi-plate wet clutch
Gear Ratios:
Refer to specific model year in manual for precise gear ratios (e.g., 1st: ~2.33, 2nd: ~1.75, 3rd: ~1.40, 4th: ~1.18, 5th: ~1.0, 6th: ~0.87).
Safety Certifications:
N/A (Competition Off-Road Motorcycle, not subject to standard road safety certifications)
Braking System:
Hydraulic disc brakes front and rear (Brembo calipers common).
Suspension Performance:
High-performance adjustable WP Suspension components designed for motocross handling and impact absorption.
Frame Construction:
Chromium-Molybdenum steel trellis frame for rigidity and strength.
Oil Change Interval:
Every 10-15 hours of riding, or as specified in manual for gearbox oil and pre-mix oil replenishment.
Air Filter Cleaning:
After every riding session or as required based on conditions.
Spark Plug Replacement:
Refer to manual, typically every 20-30 hours of riding.
Top End Rebuild Interval:
Highly variable based on use and maintenance; typically 40-80 hours for competitive use.
Gearbox Oil:
KTM recommends specific Motorex gearbox oil (e.g., Gear Oil 75W/80W or equivalent high-quality motorcycle gear oil). Capacity: ~0.7 liters.
Coolant:
If liquid-cooled: KTM Coolant or a high-quality ethylene glycol-based coolant with corrosion inhibitors (50% mixture with distilled water). Capacity: Refer to manual.
Brake Fluid:
DOT 4 or DOT 5.1 brake fluid (check manual for precise specification).
Common Wear Items:
Clutch plates, piston rings, spark plugs, air filters, wheel bearings, suspension seals, chain and sprockets.
Carburetor Tuning Variations:
Sensitivity to altitude, temperature, and humidity changes requiring periodic jetting adjustments.
Suspension Maintenance Importance:
Regular fork oil changes and seal inspections are critical for optimal performance and to prevent leaks.
