KTM 200 EXC XC XC-W 1999-2010 Workshop Service Manual

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Tipo: Motorcycle

Proveedor:

SKU: 72520

Etiquetas: 1999 200 EXC 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 KTM Misc Motorcycle Motorcycles XC XC-W

Variantes de producto

Descripción

This workshop service manual covers 200 EXC, XC, and XC-W models produced between 1999 and 2010. These motorcycles are engineered for high-performance off-road riding, offering a lightweight and agile platform with a potent 2-stroke engine. Known for their racing heritage and robust build, models in this segment are designed for aggressive trail riding and competition. The 200cc class provides a unique balance of power and manageability, making these bikes a favorite among riders seeking thrilling off-road experiences. This comprehensive manual serves as an essential resource for the maintenance, repair, and troubleshooting of your 200 EXC, XC, or XC-W. It details all major systems, including the engine, fuel, ignition, cooling, exhaust, transmission, chassis, suspension, and brakes. With step-by-step procedures, technical specifications, and diagnostic guidance, this manual empowers owners and technicians to ensure optimal performance and longevity of the vehicle. Coverage includes routine maintenance, detailed engine and transmission overhauls, suspension servicing, brake system repairs, and electrical diagnostics.

🏷️ Basic Information

Identification

Make:

Model:

200 EXC, XC, XC-W

Product Type:

Workshop Service Manual

Product Format:

PDF Download

👋 Introduction

Market Position

Segment:

High-performance off-road motorcycle segment (Enduro/Cross-Country).

Competitive Analysis

Competitors:

Competes with models from Yamaha (YZ250, WR250), Honda (CRF250X, CR250R), Suzuki (RM-Z250, DR-Z250), Kawasaki (KX250, KLX250).

Key Features

Vehicle Focus:

Lightweight, agile, and powerful 2-stroke performance for off-road competition and aggressive trail riding.

Manual Value Proposition:

Essential for owners and technicians to maintain, repair, and optimize the performance of these specialized off-road machines.

📋 Manual Details

Coverage Areas

Years Covered:

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

Page Count

Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English

Format

Format:

Digital PDF

📖 Manual Coverage

Systems Covered

Engine:

Comprehensive engine disassembly, assembly, inspection, and repair for the 200cc 2-stroke engine.

Fuel System:

Carburetor (Keihin PWK likely) tuning, cleaning, rebuilding, and fuel delivery system diagnostics.

Ignition System:

CDI ignition system, spark plug specifications, coil testing, and troubleshooting.

Cooling System:

Liquid cooling system, radiator, water pump, thermostat, and coolant specifications and flushing procedures.

Exhaust System:

Exhaust pipe, silencer, and power valve system inspection and maintenance.

Transmission:

6-speed gearbox overhaul, clutch (hydraulic actuation likely) inspection and replacement, gear shift mechanism.

Chassis:

Frame inspection, handling, and general chassis component integrity.

Suspension Front:

WP Suspension forks (likely USD type), internal component inspection, oil changes, seal replacement, and adjustment procedures.

Suspension Rear:

WP Monoshock absorber, linkage system maintenance, bearing checks, and shock absorber servicing.

Brakes Front:

Hydraulic disc brake system, caliper overhaul, pad replacement, fluid flush and bleeding, master cylinder servicing.

Brakes Rear:

Hydraulic disc brake system, caliper overhaul, pad replacement, fluid flush and bleeding, master cylinder servicing.

Wheels Tires:

Spoke tensioning, wheel bearing replacement, tire mounting and balancing, recommended tire pressures.

Electrical System:

Wiring diagrams, lighting system, battery maintenance, fuse checks, and starter system (kick-start primary).

Bodywork Fairings:

Fairing removal and installation, seat, fuel tank, and fender components.

Procedures Included

Routine Maintenance:

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

Engine Rebuild:

Top-end rebuild (piston, rings, cylinder, cylinder head), bottom-end rebuild (crankshaft, bearings, seals), power valve service.

Transmission Overhaul:

Complete gearbox disassembly, inspection of gears, shafts, and shift drum, clutch assembly and disassembly.

Suspension Servicing:

Fork oil replacement, seal head replacement, shock absorber service, linkage bearing lubrication.

Brake System Repair:

Brake caliper piston replacement, seal kits, brake line replacement, bleeding procedures.

Troubleshooting:

Diagnostic steps for common running issues, electrical faults, and mechanical problems.

Carburetor Adjustment:

Idle speed, jetting, mixture screw, and float height adjustments.

Electrical Diagnostics:

Using wiring diagrams to trace faults, testing components like stator, CDI, and regulator/rectifier (if applicable).

Technical Depth

Depth:

Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds.

Detail Level:

Detailed step-by-step instructions with torque specifications, clearances, and diagnostic procedures.

Visuals:

Likely includes diagrams, illustrations, and exploded views for clarity.

📊 Manual Specifications

File Format

Format:

Searchable:

Yes (typically, depends on PDF creation)

Printable:

Print Quality

Quality:

Digital - Quality dependent on source scan/creation, generally high for professional manuals.

Binding Type

Binding:

Not applicable (Digital Download)

Paper Type

Paper:

Not applicable (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

2-stroke, single-cylinder, liquid-cooled

Displacement:

193 cc (approx.)

Bore X Stroke:

Typically around 62.5 mm x 65 mm (exact spec to be confirmed in manual).

Power Valve:

KTM's patented exhaust power valve system for optimized torque and horsepower across the rev range.

Performance

Horsepower:

Estimated 35-40 HP (peak, varies by model year and tuning).

Torque:

Estimated 20-24 lb-ft (peak, varies by model year and tuning).

Fuel System

Carburetor:

Keihin PWK 38mm (common for this era and model, specific jetting in manual).

Fuel Type:

Unleaded gasoline, minimum 91 octane (RON + MON)/2.

Lubrication

Premix:

Required 2-stroke oil premixed with gasoline (ratio specified in manual, typically 50:1 or 60:1).

Starting System

System:

Kickstarter

🔧 Transmission

Standard

Type:

6-speed, constant mesh

Features

Clutch:

Wet multi-plate clutch, hydraulic actuation.

Gear Ratios:

Specific ratios for each gear will be detailed in the manual.

Fluid Type

Transmission Oil:

SAE 10W/30 or 10W/40 transmission oil (API GL-4 or GL-5 specification, refer to manual for precise KTM recommendation).

📐 Dimensions

Exterior

Wheelbase:

Approx. 1470-1495 mm (varies by model year and specific EXC/XC/XC-W variant).

Weights

Dry Weight:

Approx. 100-105 kg (varies by model year and specific EXC/XC/XC-W variant).

Fuel Capacity:

Approx. 7-9 liters (varies by model year and specific EXC/XC/XC-W variant).

🛡️ Safety Features

Ratings

Safety Features:

Off-road focused, minimal passive safety features beyond rider's gear. No active electronic aids like ABS or traction control on most models of this era.

💡 Technology Features

Infotainment

Infotainment System:

None. Designed for off-road performance, not comfort or convenience features.

Driver Assistance

Driver Assistance Features:

None.

Connectivity

Connectivity Features:

None.

🔧 Maintenance

Service Intervals

Oil Change:

Gearbox oil: Every 15-20 hours of operation or annually. Premix: As needed for fuel.

Air Filter Cleaning:

Every 5-10 hours of operation, or more frequently in dusty conditions.

Spark Plug Replacement:

Recommended every 20-30 hours, or as needed based on inspection.

Chain Lubrication:

Every 500-750 km, or after riding in wet conditions.

Top End Rebuild:

Recommended every 40-60 hours of hard use, or based on compression loss.

Fluid Specifications

Coolant:

Ethylene glycol-based coolant with anti-corrosion additives, mixed 50/50 with distilled water. Capacity approx. 0.8-1.0 liter.

Brake Fluid:

DOT 4 synthetic brake fluid.

Known Issues

Power Valve Sticking:

Carbon buildup can cause the power valve to stick, affecting engine performance. Requires periodic cleaning.

Clutch Slave Cylinder Leaks:

Hydraulic clutch slave cylinders can develop leaks, affecting clutch operation.

Suspension Seals:

Fork and shock seals can wear over time, leading to oil leaks and reduced damping performance.

Carburetor Jetting:

Requires careful jetting based on altitude, temperature, and exhaust/intake modifications.

📚 Vehicle History

Brand Heritage

Heritage:

KTM, an Austrian manufacturer, has a strong legacy in off-road racing, particularly motocross and enduro.

Model Evolution

Evolution:

The 200 EXC/XC/XC-W models represented KTM's offering for riders seeking a lightweight, nimble, and potent 2-stroke engine in the 200cc class, evolving through chassis updates and minor engine refinements during this period.

Production

Production Era:

1999-2010

🏆 Awards & Recognition

Recognitions

Awards:

KTM models frequently win accolades in off-road racing publications and are highly regarded by enthusiasts for their performance and durability.