KTM 200 XC-W 1999-2010 Factory Service Repair Manual

Precio habitual: $16.99
Precio de venta: $16.99
Precio habitual
Precio unitario: por

17 people are viewing this right now

Tipo: Motorcycle

Proveedor:

SKU: 78395

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

Variantes de producto

Descripción

The 200 XC-W, produced between 1999 and 2010, is a lightweight, high-performance off-road motorcycle engineered for enduro racing and demanding trail riding. Building on a rich motorsports heritage, this model features a compact, liquid-cooled 2-stroke LC2 engine, delivering approximately 40-45 horsepower through a 6-speed transmission. Its Austrian-engineered chassis, typically equipped with WP suspension and a robust chromoly steel frame, is renowned for exceptional agility and handling characteristics. Designed for off-road capability, the 200 XC-W boasts long-travel suspension, powerful hydraulic disc brakes, and an ergonomic design focused on rider control and comfort in challenging terrain. This comprehensive Factory Service Repair Manual, written in English and spanning over 500 pages, provides essential information for the maintenance and repair of your 200 XC-W from 1999 to 2010. It covers all critical systems, including the engine, transmission, chassis, electrical system, fuel, cooling, brakes, wheels, and bodywork. Detailed procedures for preventive maintenance, troubleshooting common issues, engine rebuilds, suspension setup, and carburetor tuning are included, alongside clear wiring diagrams. This manual is an indispensable resource for owners and technicians alike, ensuring the optimal performance, reliability, and longevity of the motorcycle through accurate guidance and detailed technical specifications.

🏷️ Basic Information

Identification

Make:

Model:

200 XC-W

Production Years:

1999-2010

Codes

Engine Code General:

Generation

Platform Notes:

The KTM 200 XC-W represents a specific evolution within KTM's off-road motorcycle lineup during this period, focusing on a smaller displacement, agile, and competitive package for enduro racing and trail riding.

👋 Introduction

Market Position

Segment:

Lightweight, high-performance off-road motorcycle (Enduro/Cross Country).

Competitive Analysis

Competitors General:

Competes with other small-displacement 2-stroke off-road bikes from brands like Yamaha (YZ250), Honda (CR250), Suzuki (RM250), and Kawasaki (KX250) in their respective classes, though often positioned for specific enduro applications.

Key Features

Engine Type:

Compact 2-stroke engine known for its snappy power delivery and light weight.

Chassis Design:

Austrian-engineered chassis, typically featuring WP suspension and a strong chromoly steel frame, emphasizing agility and handling.

Offroad Capability:

Designed specifically for off-road riding, with long-travel suspension, knobby tires, and a durable build.

📋 Manual Details

Coverage Areas

Covered Years:

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

Page Count

Estimated Page Count:

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, inspection, repair, and reassembly for the 2-stroke LC2 engine.

Transmission:

Gearbox, clutch, and shift mechanism maintenance and repair.

Chassis:

Frame, swingarm, suspension (forks and shock), and steering components.

Electrical System:

Ignition, lighting, charging system, wiring diagrams, and component testing.

Fuel System:

Carburetor (Keihin PWK likely), fuel tank, petcock, and fuel lines.

Cooling System:

Radiator, coolant hoses, and thermostat (if applicable).

Brakes:

Hydraulic front and rear brake systems, including calipers, master cylinders, lines, and bleeding procedures.

Wheels Tires:

Wheel bearing maintenance, spoke tensioning, and tire changing.

Bodywork:

Fairings, seat, fenders, and plastics removal and installation.

Procedures Included

Preventive Maintenance:

Regular service intervals for oil changes, filter replacements, chain adjustment, and bolt torque checks.

Troubleshooting:

Diagnostic guides for common problems related to engine performance, electrical issues, and starting difficulties.

Repair Procedures:

Step-by-step instructions for component replacement and overhaul.

Engine Rebuild:

Detailed instructions for top-end (piston, rings, cylinder) and bottom-end (crankshaft, bearings) rebuilds.

Suspension Setup:

Information on adjusting suspension sag, compression, and rebound damping.

Carburetor Tuning:

Jetting recommendations, idle speed adjustment, and float height setting.

Wiring Diagrams:

Comprehensive and clearly illustrated wiring schematics.

Technical Depth

Depth:

Comprehensive, covering everything from routine maintenance to complete engine and chassis overhauls, with detailed diagnostic procedures.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, suitable for printing all pages.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchable Text:

Likely searchable text within the PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, liquid-cooled

Displacement:

193 cc

Bore X Stroke:

62.5 mm x 65 mm (typical for this era LC2)

Compression Ratio:

Approx. 8.5:1 (typical, may vary by year/tune)

Ignition:

Digital CDI

Performance

Horsepower:

Approximately 40-45 HP (estimated, peak output)

Torque:

Approximately 20-22 lb-ft (estimated)

Fuel System

Carburetor Type:

Keihin PWK 38mm (common for this model)

Fuel Type:

Unleaded gasoline with 2-stroke oil pre-mix (typically 40:1 or 50:1 ratio, consult manual)

Oil Type:

High-quality 2-stroke synthetic or semi-synthetic engine oil.

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Optional

Optional Transmissions:

N/A (standard manual transmission)

Features

Clutch Type:

Hydraulic, multi-plate wet clutch

Final Drive:

Chain drive (520 pitch common)

Gear Ratios:

Specific gear ratios will be detailed within the manual.

Transmission Fluid:

Specialized gearbox oil (e.g., Motorex Gear Oil 75W/80 or equivalent, consult manual for specific KTM recommendation).

📐 Dimensions

Exterior

Length:

Variable, but typically around 83 inches (2100 mm).

Width:

Variable, but typically around 32 inches (820 mm) at handlebars.

Height:

Variable, but typically around 49 inches (1250 mm) at seat height.

Weights

Dry Weight:

Approximately 215-225 lbs (98-102 kg)

Wet Weight:

Approximately 235-250 lbs (107-113 kg)

Gvw Rating:

Cargo

Cargo Capacity:

N/A (motorcycle designed for off-road performance, not cargo)

🛡️ Safety Features

Ratings

Safety Ratings:

Not applicable in the traditional automotive sense; designed for off-road safety and rider control.

Active Features

Braking System:

Powerful hydraulic disc brakes front and rear for responsive stopping power.

Suspension:

Long-travel, adjustable WP suspension provides excellent control and absorbency over rough terrain.

Ergonomics:

Designed for rider comfort and control during demanding off-road use.

Passive Features

Frame Construction:

Strong chromoly steel trellis frame for rigidity and impact resistance.

Handguards:

Often included as standard or easily fitted to protect hands from impacts and debris.

💡 Technology Features

Infotainment

Infotainment Systems:

N/A (motorcycle focused on performance, no infotainment systems)

Driver Assistance

Driver Assistance Features:

N/A (no electronic driver assistance features)

Connectivity

Connectivity Features:

Engine Management

Power Valve:

Features a mechanical power valve system for optimized power delivery across the rev range, requiring proper maintenance and adjustment.

Suspension Technology

Suspension Brand:

WP Suspension (likely closed-cartridge forks and PDS or linkage-based rear shock).

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 10-15 hours of riding or annually, whichever comes first. (Consult manual for specific recommendations).

Air Filter Cleaning:

After every few rides, or more frequently in dusty conditions.

Chain Adjustment:

Check and adjust tension every 5-10 hours of riding.

Spark Plug Inspection:

Every 20-30 hours of riding.

Top End Rebuild:

Varies greatly based on usage and maintenance, typically 60-100 hours for piston/rings, 100-200+ hours for crankshaft.

Fluid Specifications

Engine Oil Type:

2-stroke engine oil (e.g., Motorex Power Synt 2T, Castrol TTS, or equivalent).

Transmission Oil Type:

Gearbox oil (e.g., Motorex Gear Oil 75W/80, Spectro 80W/90 or equivalent).

Coolant Type:

Ethylene glycol-based coolant (50/50 mix with distilled water).

Brake Fluid Type:

DOT 4 hydraulic brake fluid.

Known Issues

Common Issues General:

Wear and tear on clutch plates, power valve operation, carburetor jetting sensitivity to altitude/temperature, typical 2-stroke maintenance requirements (e.g., top-end rebuilds).

Maintenance Importance:

Due to the high-performance nature of 2-stroke engines, adherence to maintenance schedules and using high-quality lubricants is critical for longevity and performance.

📚 Vehicle History

Brand Heritage

Ktm Heritage:

KTM has a long and successful history in off-road motorsports, known for producing high-performance, race-bred motorcycles.

Model Evolution

200 Xc-W Evolution:

The 200 XC-W built upon KTM's expertise in smaller displacement 2-stroke engines, offering a balance of power and handling that appealed to riders seeking agility for technical terrain and enduro racing.

Production

Manufacturing Location:

Austria (primarily)

🏆 Awards & Recognition

Recognitions

Industry Recognition:

While specific awards for the 200 XC-W model from this era are not readily documented, KTM motorcycles have consistently received praise in off-road riding publications for their performance, handling, and durability.