🏷️ Basic Information Identification Make: KTM Model: 200 SX Model Variant: Off-road Competition Motorcycle Codes Chassis Code Range: Generally identified by VIN, specific chassis codes are model year dependent but often include 'VBK' prefix for KTM. 👋 Introduction Market Position Market Segment: Competitive Motocross / Off-road Sport Motorcycle Competitive Analysis Competitors: Honda CR250R (though 200cc is smaller displacement), Yamaha YZ250 (larger displacement but similar segment), Suzuki RM250 (larger displacement), Kawasaki KX250 (larger displacement). Key Features Performance Focus: Designed for aggressive off-road riding and competition, emphasizing power-to-weight ratio and agility. Suspension Quality: Typically equipped with high-quality WP Suspension components, renowned for performance in off-road disciplines. Engine Type: Lightweight and powerful 2-stroke single-cylinder engine, optimized for peaky power delivery. 📋 Manual Details Coverage Areas Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Page Count: 280 Manual Type Manual Type: Workshop Service Manual / Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair procedures for the 2-stroke engine, including cylinder, piston, crankshaft, connecting rod, and bearings. Fuel System: Carburetor tuning, cleaning, and rebuilding (likely Keihin PWK or similar), fuel tank, fuel lines, and fuel pump (if applicable). Ignition System: CDI unit, stator, ignition coil, spark plug specifications, troubleshooting, and testing. Cooling System: Liquid cooling system (radiators, water pump, hoses, thermostat) maintenance, bleeding, and repair. Exhaust System: Exhaust pipe and silencer inspection, repair, and maintenance. Transmission Drivetrain: Gearbox disassembly, assembly, inspection, clutch operation, chain and sprocket maintenance. Suspension Front: Front fork (WP Suspension likely) disassembly, assembly, oil changes, seal replacement, and adjustment procedures. Suspension Rear: Rear shock absorber disassembly, linkage lubrication, bearing inspection, and shock service. Brakes Front: Front brake caliper, master cylinder, brake lines, rotor inspection, and pad replacement. Brakes Rear: Rear brake caliper, master cylinder, brake lines, rotor inspection, and pad replacement. Electrical System: Wiring diagrams, lighting systems, battery maintenance, fuse box information, and basic electrical troubleshooting. Frame Chassis: Frame inspection, swingarm removal and installation, steering head bearing service. Bodywork Plastics: Fairing, seat, fuel tank cover, and fender removal/installation. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, air filter cleaning, spark plug checks, and lubrication points. Troubleshooting Diagnostics: Step-by-step diagnostic procedures for common issues related to engine performance, starting problems, electrical faults, and suspension. Engine Rebuilds: Detailed instructions for complete engine disassembly, component inspection, honing, piston ring replacement, bearing replacement, and reassembly. Suspension Rebuilds: Comprehensive guides for servicing and rebuilding front forks and rear shock absorbers, including seal and bushing replacement. Brake System Service: Brake fluid flushing, caliper servicing, master cylinder overhaul, and bleeding procedures. Electrical Diagnostics: Fault finding for lighting, ignition, and charging systems using wiring diagrams and test procedures. Technical Depth Depth Level: Comprehensive: Covers basic maintenance to complete engine and suspension rebuilds, including detailed specifications and torque values. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Typically yes for professionally created PDF service manuals, allowing for quick information retrieval. Print Quality Print Quality: Digital (high-resolution scans or original digital files), suitable for printing individual pages or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, Single Cylinder Displacement: 196 cc (approximate, often referred to as 200cc) Bore X Stroke: Typically around 62.5 mm x 65 mm (specifics may vary slightly by year/sub-model). Cooling System: Liquid-cooled Power Delivery: Known for strong mid-range and top-end power characteristics, typical of performance 2-strokes. Performance Horsepower Estimate: Approx. 35-40 HP (at crankshaft, subject to specific model year tuning). Torque Estimate: N/A (specific torque figures are less commonly published for motocross bikes compared to street bikes, focus is on HP and powerband). Fuel System Carburetor Type: Keihin PWK (often 38mm or similar size) or equivalent, with power jet systems potentially featured. Fuel Type: Unleaded gasoline (91+ octane recommended), requires 2-stroke oil pre-mix in fuel. Lubrication Premix Ratio: Typically 50:1 or 60:1 depending on the specific oil and engine wear. Manual will specify. 🔧 Transmission Standard Transmission Type: 6-speed manual sequential gearbox Clutch Type: Wet, multi-plate clutch (hydraulically actuated on later models, cable on earlier models). Features Gear Ratios: Specific ratios are detailed in the manual, optimized for motocross track performance. Final Drive: Chain drive (520 pitch chain typically) 📐 Dimensions Exterior Wheelbase: Approx. 1450-1470 mm (varies by year) Seat Height: Approx. 970-990 mm (unladen, varies by year) Weights Dry Weight: Approx. 95-100 kg (varies significantly by year and included equipment). 🛡️ Safety Features Ratings Safety Certification: N/A (Designed for closed-course competition, not street legal or road safety certified.) Active Features Braking System: Hydraulic disc brakes front and rear for reliable stopping power. Passive Features Frame Construction: Chromoly steel frame for strength and rigidity. 💡 Technology Features Infotainment Infotainment System: N/A (Pure competition...