Segment:
Lightweight off-road performance motorcycle for cross-country and enduro competition/recreation.
Target Audience:
Riders seeking a nimble, potent 2-stroke machine for challenging off-road terrain.
Competitors 2006:
Yamaha YZ250F, Honda CRF250X, Suzuki RM-Z250, Kawasaki KX250F (4-stroke equivalents); KTM 250 EXC (larger 2-stroke competitor)
Performance Focus:
Agile handling, strong low-to-mid range powerband, characteristic 2-stroke responsiveness.
Suspension Quality:
Likely equipped with high-quality WP suspension components, a hallmark of KTM motorcycles.
Off Road Design:
Purpose-built for off-road use with appropriate ground clearance, suspension travel, and rider ergonomics.
Engine:
Complete engine overhaul, top-end and bottom-end components, lubrication system, cooling system (liquid-cooled)
Transmission:
Gearbox disassembly and reassembly, clutch operation and maintenance, shift mechanism, lubrication
Fuel System:
Carburetor (likely Keihin PWK variant) tuning, cleaning, and rebuilding; fuel lines; fuel tank maintenance
Ignition System:
CDI unit, spark plug selection and maintenance, stator and coil testing
Exhaust System:
Pipe and silencer inspection and maintenance
Cooling System:
Radiator, hoses, water pump, coolant type and capacity
Suspension:
Front forks (likely WP) disassembly, seal replacement, oil type and level, rear shock absorber (WP) service, spring preload adjustment
Brakes:
Hydraulic disc brakes (front and rear), brake pad replacement, caliper service, master cylinder overhaul, brake fluid type and bleeding procedures
Electrical System:
Wiring diagrams, lighting system, battery maintenance, fuse specifications, horn
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm and linkage maintenance
Wheels And Tires:
Wheel bearing maintenance, spoke tensioning, tire pressure recommendations, recommended tire sizes
Bodywork:
Plastic panel removal and installation, seat maintenance
Routine Maintenance:
Oil changes, filter replacements, chain adjustment, spark plug checks, air filter cleaning
Troubleshooting:
Diagnostic charts for common problems, identifying causes and solutions for engine, electrical, and chassis issues
Major Repairs:
Engine rebuilds (piston, rings, crankshaft, bearings), transmission overhaul, suspension component rebuilding
Tune Up Procedures:
Carburetor jetting adjustments, ignition timing checks (if applicable), valve clearance adjustments (if applicable, though unlikely for this 2-stroke)
Component Disassembly Reassembly:
Step-by-step guides for all major components
Wiring Diagrams:
Detailed electrical schematics for troubleshooting and repair
Special Tool Identification:
Mention of specific tools required for certain procedures
Depth:
Comprehensive, suitable for professional technicians and experienced home mechanics. Covers full disassembly, assembly, diagnosis, and repair.
File Type:
PDF (Portable Document Format)
Searchability:
Likely text-searchable if OCR was performed on original scans
Image Resolution:
Variable, depends on original source. Aim for clear diagrams and text.
Original Binding:
Spiral-bound or perfect-bound (typical for factory manuals)
Original Paper:
Durable, potentially glossy paper for diagrams and images
Configuration:
Single-cylinder, 2-stroke
Displacement:
196cc (approximately)
Bore X Stroke:
Refer to manual for exact specifications, but typical for a 200cc class 2-stroke.
Cooling System:
Liquid-cooled
Power Delivery:
Strong mid-range torque and exciting top-end power characteristic of a performance 2-stroke.
Horsepower:
Estimated 35-40 HP (at crankshaft, approximate for the class)
Torque:
Refer to manual for exact figures; strong torque output for its displacement.
Carburetor Type:
Likely Keihin PWK (e.g., 36mm), known for performance and adjustability.
Fuel Type:
Unleaded gasoline, 91 octane or higher recommended
Oil Mixture:
Pre-mix 2-stroke engine oil, typically 50:1 or 40:1 ratio depending on oil quality and riding conditions. Manual will specify.
Oil Change Engine:
Refer to manual; typically every 10-15 hours of riding for hard off-road use, or based on mileage if street-legal (unlikely for XC).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions. Every 5-10 hours of riding or as needed.
Spark Plug Check:
Check every 15-20 hours. Replace as needed based on condition.
Chain Lubrication Adjustment:
Lubricate chain after every wash or every 300-500 km. Adjust tension regularly, checking every 500 km.
Coolant:
Ethylene glycol-based coolant, mixture of 50% coolant and 50% distilled water. Capacity: Refer to manual (approx. 0.7-0.9 liters).
Brake Fluid:
DOT 4 Hydraulic Brake Fluid.
Fork Oil:
Specific WP suspension oil (e.g., WP Suspension Fluid 7.5W or equivalent). Level and volume critical; refer to manual.
Transmission Oil:
Refer to manual for exact specification, e.g., API GL-4 or GL-5, viscosity 75W/90. Capacity: Refer to manual (approx. 0.6-0.8 liters).
Common Wear Items:
Piston rings, clutch plates, wheel bearings, steering head bearings, suspension seals (due to off-road abuse).
2 Stroke Specific:
Carburetor jetting sensitivity to altitude and temperature, 2-stroke oil selection and mixing accuracy.
Brand Awards:
KTM consistently receives accolades in off-road racing disciplines (e.g., Dakar Rally, motocross, enduro championships), reflecting the performance pedigree of their models.
Magazine Reviews 2006:
Review scores from contemporary off-road motorcycle publications would highlight its performance and handling characteristics. Manual can help owners achieve optimal performance reflected in these reviews.
Emissions:
Likely meets emissions standards applicable to off-road vehicles of its era and region.
