This workshop service manual covers the 200 SX, SXS, and EXC models produced between 1999 and 2006. These performance-oriented off-road motorcycles are renowned for their lightweight chassis, potent 2-stroke power delivery, and agile handling, making them a staple in motocross and competition. The SXS variants, in particular, often represented factory-prepped race editions, reflecting a strong heritage in off-road racing and commitment to delivering competitive machinery. This comprehensive 217-page manual provides detailed guidance for owners, mechanics, and technicians on the maintenance, repair, and troubleshooting of these models. It covers all essential systems, including in-depth engine overhaul procedures for the 2-stroke powerplant, transmission servicing, chassis inspection and repair, and electrical system diagnostics. Specific sections address suspension servicing, brake system maintenance, and routine procedures, ensuring that users can effectively maintain their vehicle's peak performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: 200 SX / SXS / EXC Generation Production Years: 1999-2006 Codes Model Codes: SX, SXS, EXC (Note: EXC is often grouped with SX models for service in this era, though it's a different variant) 👋 Introduction Market Position Segment: Performance Motocross / Off-Road Competition Competitive Analysis Competitors: Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (during the specified model years). Key Features Vehicle Strengths: Lightweight chassis, potent 2-stroke power delivery, strong suspension performance (WP), agile handling characteristics. The SXS variants were often factory-prepped race editions. Manual Value Target Audience: Enthusiast owners, home mechanics, and professional technicians working on KTM 200 SX, SXS, and EXC models from 1999 to 2006. Benefits: Provides essential information for maintaining peak performance, diagnosing issues, and executing repairs, saving time and money compared to relying solely on dealer services. 📋 Manual Details Coverage Areas Engine Coverage: 2-stroke engine overhaul, top-end and bottom-end rebuild, carburetor tuning, ignition system, cooling system (if applicable to specific variants). Transmission Coverage: Clutch service, gearbox inspection and repair, shift mechanism, gear ratios. Chassis Coverage: Frame inspection, suspension (forks, rear shock), swingarm, linkage, steering head bearings, wheel bearings, brake system overhaul, cooling system maintenance. Electrical Coverage: Wiring diagrams, lighting system, ignition system, battery maintenance, troubleshooting electrical faults. Page Count Total Pages: 217 Manual Type Type: Workshop Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Management: Comprehensive coverage of the 2-stroke engine, including carburetor settings (e.g., Keihin PWK), jetting recommendations, reed valve maintenance, cylinder and piston inspection, crankshaft bearing replacement, and exhaust system tuning. Suspension And Handling: Detailed procedures for KTM's renowned WP Suspension components, including fork seal replacement, oil changes, spring rate identification, rear shock absorber servicing, linkage maintenance, and steering head bearing adjustment. Braking System: Service procedures for hydraulic disc brakes (front and rear), including caliper overhaul, master cylinder service, brake fluid replacement (DOT 4 typically), pad inspection and replacement, and bleeding procedures. Cooling System: Maintenance and servicing of the liquid cooling system, including radiator care, hose inspection and replacement, water pump seal inspection, and coolant type recommendations. Fuel And Ignition: Carburetor disassembly, cleaning, and reassembly; ignition coil testing, spark plug selection and gap settings, CDI unit troubleshooting. Procedures Included Routine Maintenance: Chain cleaning and lubrication, air filter cleaning and oiling, spark plug replacement, general inspection checklists. Engine Rebuild: Complete top-end rebuilds (piston, rings, cylinder), bottom-end rebuilds (crankshaft, bearings, seals), cylinder head service, and porting information for performance enhancement. Transmission Overhaul: Gearbox disassembly, inspection of gears and shift forks, clutch plate replacement, pressure plate adjustments, and lubrication. Suspension Servicing: Fork leg disassembly, oil viscosity and level specifications, seal installation, shock absorber charging and valving adjustments (where applicable). Troubleshooting Guides: Diagnostic charts for common engine performance issues, electrical faults, starting problems, and suspension malfunctions, with step-by-step diagnostic procedures. Technical Depth Depth: Comprehensive, covering all aspects from basic maintenance and adjustments to complete engine, transmission, and suspension overhauls. Includes detailed torque specifications, clearances, and diagnostic procedures. 📊 Manual Specifications File Format Quality: High-resolution PDF, ensuring clear diagrams and text. Searchable text for quick information retrieval. Print Quality Printability: Designed for easy printing of individual sections or the entire manual for workshop use. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, single-cylinder Displacement: Approx. 193 cc (exact may vary slightly by year/model designation) Bore X Stroke: Typically around 62.5 mm x 65 mm Cooling System: Liquid-cooled Fuel Delivery: Carburetor (commonly Keihin PWK 36 or similar) Performance Horsepower Estimate: Estimated 35-40+ HP depending on tune and specific model variant (SX vs. SXS). Torque Estimate: Torque figures not typically emphasized in marketing for this class, but focused on broad powerband. Fuel System Recommended Fuel: Unleaded gasoline with a minimum octane rating of 95 (RON+MON)/2 or higher. Premix with high-quality 2-stroke oil. Air Filter: High-flow, washable foam air filter. Requires regular cleaning and oiling. Engine Internals Piston Type: Typically a single-ring, performance-oriented piston. 🔧 Transmission Standard Type: 6-speed...