This manual covers the 200 SX, an off-road competition motorcycle produced for model years 1999 through 2010. Renowned for its potent 2-stroke engine and agile handling, the 200 SX is engineered for aggressive riding and performance in motocross and off-road disciplines. Its lightweight construction, combined with high-quality suspension components, contributes to its reputation for delivering exceptional power-to-weight ratio and on-track capability. A strong heritage in off-road racing is evident in the design and performance of this model, making it a competitive choice for riders seeking peak performance. The scope of this comprehensive workshop service and repair manual is to provide detailed guidance for the maintenance, diagnosis, and repair of the 200 SX. It covers all essential systems, including engine mechanicals, fuel and ignition systems, cooling, exhaust, transmission, front and rear suspension, braking systems, and the electrical system. The manual details routine maintenance procedures, troubleshooting steps for common issues, and in-depth instructions for engine and suspension rebuilds. With its extensive coverage, this manual serves as an indispensable resource for owners, mechanics, and technicians aiming to ensure the optimal performance and longevity of their 200 SX. 🏷️ 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...