KTM 200 XC 1999-2010 Workshop Service Manual for Repair

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Tipo: Motorcycle

Proveedor:

SKU: 80976

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

Variantes de producto

Descripción

This manual covers the 200 XC, a performance-oriented off-road motorcycle produced from 1999 through 2010. Renowned for its lightweight agility and potent 2-stroke engine performance, the 200 XC is engineered for competitive off-road riding and aggressive trail use. A heritage in off-road racing underpins the development of this model, emphasizing a strong power-to-weight ratio and robust construction, characteristic of a dedication to off-road excellence. This comprehensive workshop service and repair manual provides essential information for technicians, DIY mechanics, and enthusiasts. It details maintenance procedures, troubleshooting guidance, technical specifications, and disassembly/reassembly instructions for all major systems, including the engine, transmission, chassis, brakes, and electrical components. With 280 pages of detailed content, this manual empowers users to maintain peak performance, diagnose issues efficiently, and conduct all necessary repairs, ensuring the longevity and optimal operation of the 200 XC.

🏷️ Basic Information

Identification

Make:

Model:

200 XC

Model Years Covered:

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

Engine Variant Covered:

200cc (specific variant details to be confirmed via manual content)

👋 Introduction

Market Position

Segment:

Off-Road Competition (XC - Cross Country)

Category:

Performance Off-Road Motorcycle

Competitive Analysis

Competitors:

Husqvarna WR250, Gas Gas EC250, Beta RR250, Yamaha YZ250 (depending on specific year comparisons, though 200cc is a niche)

Key Features

Vehicle Focus:

Lightweight, agile, potent 2-stroke performance for off-road racing and aggressive trail riding.

Manual Benefit:

Enables owners and technicians to maintain peak performance, diagnose issues efficiently, and perform all necessary repairs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service and Repair

Target Audience:

KTM Technicians, DIY Mechanics, Enthusiasts

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English (presumed, standard for KTM technical documentation)

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, carburetor adjustment, ignition system, cooling system (if applicable), lubrication system.

Transmission:

Clutch operation, gearbox disassembly and reassembly, shift mechanism, lubrication.

Chassis:

Frame inspection and repair, suspension (forks, rear shock), steering system, wheels and hubs.

Brakes:

Hydraulic brake system (front and rear calipers, master cylinders, lines), pad replacement, fluid bleeding, rotor inspection.

Electrical:

Wiring diagrams, lighting system, ignition system components, battery maintenance, charging system (stator, rectifier).

Bodywork:

Fairing removal and installation, seat, fuel tank, fenders.

Controls:

Throttle assembly, clutch lever, brake lever, footpegs, handlebars.

Procedures Included

Maintenance:

Regular service intervals, lubrication points, filter changes, spark plug replacement, chain adjustment.

Repair:

Step-by-step instructions for all major component repairs and replacements.

Troubleshooting:

Diagnostic flowcharts and common problem identification for various systems.

Disassembly Reassembly:

Detailed procedures for component removal and reinstallation.

Technical Depth

Depth:

Comprehensive: Covers routine maintenance, advanced diagnostics, and complete engine/component rebuilds.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable PDF (likely, typical for professional manuals)

Print Quality

Quality:

High-resolution (expected for professional workshop manuals, suitable for printing)

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

2-Stroke, Single Cylinder

Displacement:

193cc (approximate for KTM 200 models of this era)

Bore X Stroke:

62.5 mm x 64 mm (typical for KTM 200s)

Cooling System:

Liquid-Cooled

Performance

Horsepower:

Approximately 35-40 HP (estimate based on era and displacement)

Torque:

Not readily available for specific model year, but expected to provide strong mid-range power.

Fuel System

Carburetor:

Keihin PWK 36 (typical for KTM 200 XC of this period)

Fuel Type:

Unleaded Gasoline (91 octane or higher recommended)

Oil Mixture:

Pre-mix (typically 50:1 or 40:1 with high-quality 2-stroke oil, refer to manual for exact specification)

🔧 Transmission

Standard

Type:

6-Speed Manual

Clutch:

Wet Multi-Plate Clutch

Features

Gear Ratios:

Specific gear ratios are detailed within the workshop manual.

Final Drive:

Chain Drive

📐 Dimensions

Exterior

Wheelbase:

Approximately 1460 mm (57.5 inches) - subject to variation by year.

Weights

Dry Weight:

Approximately 100-105 kg (220-231 lbs) - subject to variation by year.

Fuel Capacity:

Approximately 8-10 Liters (2.1-2.6 US Gallons) - subject to variation by year.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles typically do not undergo standardized crash testing like passenger cars).

Active Features

Braking:

Hydraulic Disc Brakes (Front and Rear)

Passive Features

Frame Construction:

Chromoly Steel Trellis Frame (characteristic of KTM off-road bikes)

💡 Technology Features

Infotainment

Features:

N/A (Basic off-road motorcycle, focus is on performance and durability, not electronics beyond essential functions).

Driver Assistance

Features:

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change:

Refer to manual for specific interval based on riding conditions; typically every 10-15 hours of hard use or annually.

Air Filter Cleaning:

Frequent cleaning recommended for off-road use; every 5-10 hours or as needed.

Spark Plug Replacement:

Refer to manual; typically every 20-40 hours of operation.

Fluid Specifications

Engine Oil Transmission Oil:

KTM specifies specific gearbox oil (e.g., Motorex Gear Oil 80W) and 2-stroke premix oil. Manual will list exact specifications.

Coolant:

Ethylene Glycol Based Coolant (50/50 mix with distilled water) - specific type detailed in manual.

Brake Fluid:

DOT 4 Hydraulic Brake Fluid (refer to manual for precise type and brand recommendations).

Known Issues

Common Wear Items:

Clutch plates, piston rings, wheel bearings, steering head bearings, suspension seals.

Potential Failures:

Carburetor jetting issues, ignition coil failure, exhaust power valve sticking (with improper maintenance).

Parts Information

Part Numbers:

The manual will contain detailed part numbers for all components and consumables.

📚 Vehicle History

Brand Heritage

Heritage:

KTM AG is an Austrian manufacturer renowned for its off-road motorcycles, known for performance and racing prowess.

Model Evolution

Development:

The 200 XC models represent KTM's commitment to the competitive off-road market, offering a potent blend of power and agility in a 200cc package.

Production

Covering a significant decade of the 200 XC's production history.

🏆 Awards & Recognition

Recognitions

Brand Recognition:

KTM is consistently recognized for its dominance in off-road racing disciplines (Motocross, Enduro, Rally).

Ratings

Model Performance:

The 200 XC series is generally lauded for its strong power-to-weight ratio and aggressive off-road capabilities.