KTM 200 XC-W 2006 Service Repair Workshop Manual

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The 2006 200 XC-W is a performance-oriented off-road motorcycle engineered for demanding enduro and trail riding. As part of the esteemed XC-W lineage, it embodies the 'Ready to Race' philosophy,...

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Taper: Motorcycle

Distributeur:

UGS: 76648

Mots clés: 200 XC-W 2006 KTM Misc Motorcycle Motorcycles

Variantes de produits

Description

The 2006 200 XC-W is a performance-oriented off-road motorcycle engineered for demanding enduro and trail riding. As part of the esteemed XC-W lineage, it embodies the 'Ready to Race' philosophy, offering a lightweight, agile platform powered by a potent 196 cc two-stroke engine. Its design emphasizes powerful acceleration and precise handling, making it a formidable choice for competitive off-road events and challenging terrain. The motorcycle features a robust chromoly steel frame, adjustable WP suspension, and hydraulic disc brakes, all contributing to its exceptional control and rider confidence in diverse off-road conditions. This comprehensive Service Repair Workshop Manual provides full service and repair instructions for the 2006 200 XC-W. It covers all essential systems, including detailed procedures for engine overhaul, fuel and ignition systems, cooling, transmission, clutch, brakes, suspension, and electrical components. The manual also includes routine maintenance schedules, troubleshooting guides for common issues, and disassembly/assembly instructions for all major parts. It is an invaluable resource for owners, mechanics, and technicians seeking to maintain, repair, and optimize the performance of their 200 XC-W, ensuring its reliability and longevity.

🏷️ Basic Information

Identification

Make:

Model:

200 XC-W

Year:

Vehicle Type:

Off-road Motorcycle

Engine Designation:

200 XC-W

👋 Introduction

Market Position

Market Segment:

Performance off-road/enduro competition motorcycle

Competitive Analysis

Key Competitors:

Yamaha WR250F, Honda CRF250X, Suzuki RM-Z250, Kawasaki KX250

Key Features

Lightweight, agile, powerful two-stroke engine tailored for aggressive off-road riding and competition

Intended Use:

Enduro, trail riding, motocross (with modifications), competitive off-road events

📋 Manual Details

Coverage Areas

Coverage:

Full service and repair instructions

Page Count

Page Count:

N/A (PDF Download)

Manual Type

Manual Type:

Service Repair Workshop Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, internal components, tuning, and diagnostics

Fuel System:

Carburetor service, fuel delivery, jetting, fuel tank, and fuel lines

Ignition System:

CDI unit, spark plug, ignition timing, and troubleshooting

Cooling System:

Radiator, coolant flow, thermostat, and fan (if applicable)

Exhaust System:

Exhaust pipe, silencer, and related components

Transmission:

Gearbox internals, clutch operation, gear shift mechanism, and lubrication

Clutch:

Clutch assembly, plates, springs, and hydraulic system (if applicable)

Frame:

Frame structure, welds, and component mounting points

Suspension:

Front fork (WP), rear shock absorber (WP), adjustments, and rebuild procedures

Brakes:

Front and rear brake systems (hydraulic disc), caliper service, master cylinders, and fluid replacement

Electrical System:

Wiring diagrams, lighting, battery, starter system (if applicable), and fuse box

Wheels And Tires:

Rim inspection, spoke tension, tire mounting, and balancing

Bodywork And Plastics:

Fairings, seat, fenders, and graphical elements

Procedures Included

Maintenance:

Routine servicing, oil changes, filter replacements, chain maintenance, and lubrication

Troubleshooting:

Diagnostic procedures for common and uncommon issues, fault finding charts

Repair:

Step-by-step repair instructions for all major components and systems

Rebuilds:

Engine and gearbox rebuilds, suspension overhauls

Disassembly And Assembly:

Detailed procedures for taking apart and reassembling the motorcycle

Specifications And Torques:

Torque values for all fasteners, clearance specifications, and tolerances

Technical Depth

Depth:

Comprehensive, from basic maintenance to full engine rebuilds

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution, 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:

2-stroke

Displacement:

196 cc

Bore X Stroke:

62.5 x 65 mm

Cylinder Arrangement:

Single-cylinder

Cooling System:

Liquid-cooled

Power Valve:

Electronically controlled exhaust power valve (EPV)

Compression Ratio:

8.7:1 (approx.)

Performance

Horsepower:

Approx. 38-40 HP (estimated, actual figures vary)

Torque:

Approx. 24-26 Nm (estimated, actual figures vary)

Fuel System

Carburetor:

Keihin PWK 38 Air Stripper

Fuel Type:

Unleaded gasoline with 2-stroke oil (premix)

Premix Ratio:

1:40 or 1:50 (depending on oil manufacturer and riding conditions)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-plate clutch, hydraulically operated

Features

Gear Ratios:

Specific gear ratios are detailed within the manual.

Final Drive:

Chain drive

Transmission Oil Type:

KTM recommends specific gear oil; consult manual for exact specification (e.g., SAE 10W/15W or 80W).

📐 Dimensions

Exterior

Length:

Approx. 2100 mm

Width:

Approx. 800 mm

Height:

Approx. 1250 mm

Wheelbase:

Approx. 1440 mm

Weights

Dry Weight:

Approx. 99 kg

Fuel Tank Capacity:

Approx. 9 liters (including reserve)

Seat Height:

Approx. 970 mm

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles are not typically rated by consumer safety organizations like cars; adherence to mechanical integrity is paramount)

Active Features

Braking System:

Hydraulic disc brakes (front and rear) for reliable stopping power

Suspension Control:

Adjustable WP suspension for optimal handling and stability

Passive Features

Frame Design:

Robust, lightweight chromoly steel frame for chassis rigidity and rider control

💡 Technology Features

Infotainment

Infotainment System:

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

Driver Assistance

Traction Control:

Connectivity

Bluetooth Connectivity:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual for specific intervals, typically every 15-20 engine hours for off-road use.

Air Filter Cleaning:

Frequent cleaning/replacement recommended based on riding conditions (e.g., every 5-10 hours)

Spark Plug Replacement:

Refer to manual for recommended intervals; typical for 2-strokes is more frequent than 4-strokes.

Top End Rebuild Interval:

Highly dependent on usage; manual will specify for optimal performance (e.g., 50-100 hours for piston and rings).

Fluid Specifications

Engine Oil Type:

High-quality 2-stroke premix oil (e.g., Motorex, Castrol, etc.)

Transmission Oil Grade:

SAE 10W/15W or SAE 80W gear oil (check manual for specific grade and capacity)

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0)

Brake Fluid Type:

DOT 4 hydraulic brake fluid

Known Issues

Common Wear Items:

Piston rings, spark plugs, clutch plates, chain and sprockets, wheel bearings, swingarm bearings due to off-road stress.

Power Valve Maintenance:

Carbon buildup can affect power valve operation; requires regular cleaning as per manual.

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM has a strong heritage in off-road racing, known for its 'Ready to Race' philosophy and high-performance motorcycles.

Model Evolution

200 Xc-W Lineage:

The XC-W (Cross Country - Winning) line represents KTM's dedication to versatile off-road competition, evolving from their motocross and enduro roots.

Production

Manufacturing Location:

Austria (typically for KTM models)

🏆 Awards & Recognition

Recognitions

Performance Acclaim:

KTM 2-stroke models of this era were consistently praised for their potent power delivery and handling in competitive off-road disciplines. Specific awards for the 200 XC-W model are tied to its championship successes in various off-road racing series.

Ratings

User Reviews:

Enthusiast forums and reviews typically highlight its strong low-to-mid range power, agile chassis, and suitability for technical terrain.