The 200 SXS is a high-performance, lightweight competition motocross and off-road motorcycle, renowned for its agility and powerful two-stroke engine. Produced across multiple model years from 1999 to 2010, this model embodies a heritage of off-road prowess, often serving as a factory replica or works edition with enhanced specifications. Its design focuses on delivering exceptional handling and rider feedback, making it a favored choice for enthusiasts and racers seeking a competitive edge in demanding terrain. This comprehensive Factory Service Repair Manual provides essential information for the maintenance, repair, and troubleshooting of the 200 SXS. It covers all critical systems, including detailed procedures for engine disassembly and reassembly, transmission servicing, suspension tuning, brake system overhauls, and electrical diagnostics. The manual is designed to assist owners, mechanics, and technicians by offering in-depth technical specifications, torque values, diagnostic flowcharts, and step-by-step instructions, ensuring the optimal performance and longevity of the vehicle. 🏷️ Basic Information Identification Make: KTM Model: 200 SXS Model Variant: SXS Codes Vin Code: Not specified in product info, but typically 17 characters starting with 'VBK' for KTM motorcycles. Engine Code: Not explicitly stated, but likely a specific designation for the 200cc two-stroke engine used in this model. 👋 Introduction Market Position 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. Competitive Analysis Competitors: Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (during its respective production years). Key Features 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. 📋 Manual Details Coverage Areas 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). Page Count Estimated Page Count: Estimated 300-500+ pages (typical for comprehensive factory service manuals). Manual Type Manual Type: Factory Service Repair Manual Language Language: English (standard for factory manuals unless otherwise specified). Format Format: PDF Download 📖 Manual Coverage Systems Covered 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. Procedures Included 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. Technical Depth 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. 📊 Manual Specifications File Format File Format: PDF Searchability: Likely text-searchable PDF for easy navigation. Print Quality Print Quality: High-resolution, suitable for printing key sections or the entire manual. Binding Type Binding Type: N/A (Digital PDF download). Paper Type Paper Type: N/A (Digital PDF download). ⚙️ Engine Specifications Primary Engine 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). Performance 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 System Fuel Type: Unleaded gasoline (minimum 95 RON). Carburetor Model: Likely Keihin PWK 38 AS or similar. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate clutch Features Gear Ratios: Specific ratios will be detailed in the manual for each model year. Final Drive: Chain drive 📐 Dimensions Exterior Seat Height: Approximately 37.6 inches (955 mm) - varies slightly by year. Ground Clearance: Approximately 13.8 inches (350 mm) - varies slightly by year. Weights...