The 200 SX, a 2-stroke motocross motorcycle produced between 1999 and 2003, embodies a 'Ready to Race' philosophy with its agile handling and potent power delivery. Designed for entry-level to intermediate motocross competition, this model offers a compelling blend of 125cc class maneuverability and the performance characteristics of larger displacement bikes. Its liquid-cooled, single-cylinder 194cc engine, coupled with a 6-speed transmission and advanced suspension, provides riders with a competitive edge on the track. The robust steel perimeter frame ensures durability and responsiveness, making the 200 SX a capable machine for both amateur racers and dedicated off-road enthusiasts. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and servicing of all 200 SX models from 1999 to 2003. It covers essential areas including engine overhaul, transmission servicing, chassis and suspension maintenance, brake system repairs, and electrical system troubleshooting. The manual includes step-by-step procedures, technical specifications, torque values, and diagnostic information crucial for qualified mechanics and experienced DIY users. Its purpose is to ensure the optimal performance, reliability, and longevity of your 200 SX through proper care and repair. 🏷️ Basic Information Identification Make: KTM Model: 200 SX Model Variant: 2-Stroke Motocross Production Years Covered: 1999, 2000, 2001, 2002, 2003 Codes Chassis Code: Not explicitly stated, typical for off-road bikes of this era. Engine Code: Not explicitly stated, but refers to the specific 200cc 2-stroke engine. 👋 Introduction Market Position Motorcycle Segment: Entry-level to intermediate motocross/off-road competition. Target Audience: Amateur racers, recreational riders, mechanics specializing in off-road motorcycles. Competitive Analysis Competitors: Yamaha YZ250, Suzuki RM250, Honda CR250R, Kawasaki KX250 (though often categorized slightly differently due to displacement). Key Features Performance Focus: Agile handling, potent 2-stroke power delivery, competitive pricing for its class. Brand Philosophy: KTM's 'Ready to Race' ethos emphasizes performance and off-road capability. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Repair and Service Vehicle Scope: All KTM 200 SX models from 1999-2003 Page Count Estimated Pages: Likely 300-500 pages (typical for comprehensive workshop manuals). Manual Type Type: Workshop Service Manual Language Language: English (assumed based on common market) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top-end and bottom-end procedures, carburetor tuning, cooling system, ignition system, exhaust system. Transmission: Clutch operation and adjustment, gearbox disassembly and reassembly, gear shift mechanism, lubrication. Chassis: Frame inspection and repair, suspension (forks and rear shock) overhaul and adjustments, wheel bearing replacement, steering head bearing service. Brakes: Hydraulic brake system maintenance, caliper service, master cylinder overhaul, fluid replacement, pad replacement. Electrical: Wiring diagrams, lighting system, ignition system components, troubleshooting electrical faults, battery maintenance. Bodywork And Plastics: Fairing removal and installation, seat maintenance, fuel tank, fender service. Procedures Included Maintenance: Routine servicing, oil changes, filter replacements, chain adjustment, spark plug service, pre-ride inspections. Troubleshooting: Diagnostic procedures for common issues, electrical fault finding, engine performance problems. Repair: Component-level repair and replacement, engine rebuilds, suspension servicing, brake system overhauls. Disassembly And Assembly: Step-by-step instructions for removing and refitting major assemblies and components. Specifications And Measurements: Torque values, clearances, tolerances, diagnostic readings. Technical Depth Depth: Comprehensive; suitable for qualified mechanics and experienced DIY enthusiasts. Covers detailed diagnostic and repair procedures beyond basic owner's manual information. 📊 Manual Specifications File Format File Type: PDF Searchable Text: Generally expected for professionally produced PDF manuals. Printable: Yes Print Quality Image Resolution: High-resolution diagrams and illustrations expected. Binding Type Type: N/A (Digital PDF) Paper Type Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, 2-stroke Displacement: 194 cc (approx.) Bore X Stroke: Typically around 62.5 mm x 65 mm (specific to the 200 SX model). Cooling System: Liquid-cooled Ignition System: Electronic CDI (Capacitor Discharge Ignition) Performance Horsepower: Estimated 35-40 HP at peak (varies with tuning and specific year). Torque: Specific figures not readily available, but known for strong mid-range power. Fuel System Carburetor: Mikuni TM Series (e.g., TM38) or Keihin PWK, depending on exact model year. Fuel Type: Unleaded gasoline (minimum 95 octane recommended), mixed with 2-stroke oil (e.g., 1:30 to 1:50 ratio). Premix Ratio: Refer to manual for precise recommendations; typically 1:40. 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Wet multi-plate clutch, hydraulically operated. Optional Type: N/A Features Gear Ratios: Specific ratios will be detailed in the manual; designed for motocross performance. Final Drive: Chain drive (specific sprocket sizes will be in the manual). 📐 Dimensions Exterior Wheelbase: Approximately 1450 mm (57.1 inches). Seat Height: Approximately 960 mm (37.8 inches). Ground Clearance: Approximately 360 mm (14.2 inches). Weights Dry Weight: Approximately 95 kg (209 lbs). Fuel Tank Capacity: Approximately 8 liters (2.1 US gallons). 🛡️ Safety Features Ratings Crash Test Results: N/A for off-road motorcycles. Active Features Brakes: Hydraulic disc brakes front and rear. Suspension: WP suspension (often USD forks and monoshock rear) designed for off-road control and impact absorption. Passive Features Frame Construction: Steel perimeter frame designed for strength and...