KTM 200 MXC 1999-2010 Workshop Service Manual for Repair

Normaler Preis: $16.99
Verkaufspreis: $16.99
Normaler Preis
Grundpreis: pro

This manual covers the 200 MXC, a performance off-road motorcycle produced from 1999 through 2010. Known for its lightweight chassis and potent two-stroke engine, the 200 MXC was engineered for...

19 people are viewing this right now

Typ: Motorcycle

Anbieter:

Art.-Nr: 80973

Stichworte: 1999 200 MXC 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 KTM Misc Motorcycle Motorcycles

Produktvarianten

Beschreibung

This manual covers the 200 MXC, a performance off-road motorcycle produced from 1999 through 2010. Known for its lightweight chassis and potent two-stroke engine, the 200 MXC was engineered for versatility, excelling in both motocross and enduro riding. Building on a strong heritage in off-road competition, this model offered a compelling blend of power and agility, competing against established offerings from major manufacturers. Its design prioritized rider control and dynamic performance, making it a capable machine for demanding off-road conditions. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and overhaul of the 200 MXC. It covers all essential systems, including the engine, fuel, ignition, cooling, exhaust, transmission, suspension, brakes, wheels, electrical, and chassis. Within its 280 pages, you will find procedures for routine maintenance, troubleshooting common issues, complete engine rebuilds, and specialized tasks such as suspension and brake system servicing. This manual is an indispensable resource for owners, mechanics, and technicians seeking to ensure the optimal performance and longevity of their 200 MXC.

🏷️ Basic Information

Identification

Make:

Model:

200 MXC

Production Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

👋 Introduction

Market Position

Segment:

Performance Off-Road Motorcycle (Enduro/Motocross)

Competitive Analysis

Competitors:

Competed against models from Yamaha (YZ250/WR250), Honda (CR250/XR250), Suzuki (RM250/DR-Z250), Kawasaki (KX250/KDX250), and other European manufacturers in the 200cc class segment.

Key Features

Ktm Heritage:

KTM's reputation for potent two-stroke engines and competitive off-road performance.

Model Focus:

The 200 MXC was designed as a versatile off-road machine, suitable for both competitive motocross and enduro riding, often praised for its lightweight chassis and torquey engine.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service Manual for Repair

Page Count

Page Count:

Manual Type

Type:

Service Manual

Language

Language:

English (Assumed, standard for KTM workshop manuals of this era)

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, repair, and reassembly of the engine, including cylinder, piston, connecting rod, crankshaft, valves, camshafts, and timing components.

Fuel System:

Carburetor tuning, cleaning, and overhaul (likely Keihin or Mikuni based on model year), fuel pump, fuel lines, and tank maintenance.

Ignition System:

Ignition coil testing, spark plug specifications, CDI unit diagnostics, and wiring schematics for the ignition system.

Cooling System:

Radiator, cooling fan, water pump, thermostat, and coolant hose inspection and replacement procedures.

Exhaust System:

Exhaust pipe and silencer inspection, repair, and repacking (if applicable for off-road use).

Transmission Drivetrain:

Gearbox disassembly, inspection, and repair; clutch operation, adjustment, and replacement; chain and sprocket wear assessment and replacement.

Suspension Front:

Fork disassembly, oil change, seal replacement, spring inspection, and adjustment procedures for WP USD forks.

Suspension Rear:

Monoshock absorber inspection, service, and adjustment; linkage system lubrication and bearing checks; swingarm maintenance.

Brakes Front:

Brake caliper overhaul, pad replacement, master cylinder service, brake line inspection, and bleeding procedures.

Brakes Rear:

Rear brake caliper overhaul, pad replacement, master cylinder service, brake line inspection, and bleeding procedures.

Wheels Hubs:

Spoke tension adjustment, rim inspection, hub bearing replacement, and tire mounting/dismounting.

Electrical System:

Wiring diagrams, lighting system maintenance, battery testing and replacement, starter motor checks, and general electrical troubleshooting.

Frame Chassis:

Frame inspection for damage, steering head bearing service, subframe checks, and footpeg mount inspections.

Bodywork:

Fairing removal and installation, seat maintenance, fender replacement, and graphics application/removal.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, air filter cleaning/replacement.

Troubleshooting:

Step-by-step diagnostic procedures for common starting issues, running problems, and system malfunctions.

Engine Rebuild:

Detailed instructions for full engine disassembly, component measurement, and reassembly for major overhauls.

Suspension Service:

Front fork oil change, seal replacement, and rear shock absorber servicing.

Brake System Repair:

Brake bleeding, pad and disc replacement, and caliper/master cylinder servicing.

Carburetor Overhaul:

Complete cleaning, adjustment, and jetting guidance for the stock carburetor.

Electrical Diagnostics:

Troubleshooting electrical faults using wiring diagrams and component testing methods.

Technical Depth

Depth:

Comprehensive; covers everything from basic maintenance to complete engine and chassis rebuilds, including detailed specifications and torque values.

📊 Manual Specifications

File Format

File Format:

Searchability:

Likely text-searchable if digitally generated or properly OCR'd.

Print Quality

Print Quality:

High-resolution scans suitable for printing.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke single-cylinder

Displacement:

194 cc (bore x stroke typically around 62.5 mm x 65 mm, but confirm specific model variant)

Bore:

Approx. 62.5 mm

Stroke:

Approx. 65 mm

Compression Ratio:

Typically around 8.5:1 to 9.5:1 for a 2-stroke of this era, subject to specific tuning.

Carburetor:

Likely a Keihin PWK or Mikuni TM series, 38mm common for this class.

Performance

Horsepower Estimated:

Approx. 35-40 HP (at crank, typical for this engine size and class)

Torque Estimated:

Approx. 25-30 Nm (at crank, typical)

Fuel System

Fuel Type:

Unleaded gasoline with 2-stroke oil pre-mix (e.g., 50:1 or 40:1 ratio depending on oil and usage).

Premix Ratio:

Refer to manual for specific recommendation (e.g., 1:40 or 1:50).

🔧 Transmission

Standard

Transmission Type:

6-speed manual

Features

Clutch Type:

Wet multi-plate clutch, hydraulically actuated.

Final Drive:

Chain drive

📐 Dimensions

Exterior

Frame Type:

Chromoly steel perimeter frame.

Weights

Dry Weight Estimated:

Approx. 95-105 kg (varying slightly by year and specific configuration)

🛡️ Safety Features

Ratings

Safety Standard:

Off-road competition vehicles are not typically subjected to DOT or Euro NCAP crash ratings. Safety features focus on rider control and crash mitigation typical for dirt bikes.

Active Features

Braking System:

Hydraulically operated disc brakes front and rear, offering strong stopping power.

💡 Technology Features

Infotainment

Infotainment System:

N/A (This is a performance off-road motorcycle, no infotainment features expected).

Driver Assistance

Driver Assistance Features:

N/A (No electronic driver assistance systems typically found on this type of motorcycle).

Connectivity

Connectivity Features:

N/A (No electronic connectivity features).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Refer to manual; typically every 15-20 hours of riding for rigorous off-road use, or annually.

Air Filter Cleaning:

Clean after every few rides, or more frequently in dusty conditions. Replace as needed.

Spark Plug Inspection:

Inspect every 20-30 hours of riding. Replace if fouled or worn.

Chain Lubrication:

Lubricate every ride, or every 300-500 km depending on conditions.

Chain Tension Adjustment:

Check and adjust every 500-1000 km or as needed.

Fluid Specifications

Engine Oil Type:

Dedicated 2-stroke engine oil, JASO FD or higher specification. Refer to manual for specific brand/type.

Transmission Oil Type:

Motorex Gear Oil 10W/40 or equivalent SAE 80W/90 transmission oil (confirm specific viscosity from manual).

Fork Oil Type:

WP Suspension Fluid or equivalent, typically SAE 5W or 7.5W. Refer to manual for specific viscosity and quantity.

Coolant Type:

Distilled water with a high-quality anti-freeze/anti-corrosion additive (e.g., 50% mix).

Known Issues

Power Valve Sticking:

Common on 2-stroke engines of this era, the power valve can accumulate carbon and stick, affecting performance. Regular cleaning is recommended.

Clutch Wear:

Aggressive riding can lead to premature clutch wear. Regular inspection of plates and springs is advised.

Suspension Seal Leaks:

Fork and shock seal leaks can occur with hard use, requiring seal replacement.

📚 Vehicle History

Brand Heritage

Ktm Offroad Focus:

KTM has a long-standing and dominant history in off-road racing, including motocross and enduro, since the 1970s.

Model Evolution

200 Mxc Lineage:

The 200 MXC was part of KTM's successful range of off-road motorcycles, evolving from earlier 125 and 250 models, offering a displacement niche.

Production

Manufacturing Location:

Austria (KTM AG)

🏆 Awards & Recognition

Recognitions

Offroad Magazine Reviews:

KTM models from this era often received high marks in off-road publications for their performance and handling, though specific awards for the 200 MXC model would require historical research.