Segment:
Off-road motorcycle, Enduro/Cross Country competition focus.
Competitors 2006:
Other 200cc off-road models from brands like Yamaha (YZ250F, WR250F), Honda (CRF250X), Suzuki (RM-Z250, RMX450Z), Kawasaki (KX250F, KLX300R).
Ktm Brand Philosophy:
Known for 'Ready to Race' heritage, high-performance off-road machines with advanced suspension and powerful engines.
Ktm 200Xcw Niche:
The 200 XC-W is known for offering a potent blend of a 250cc's power with the nimbleness and ease of handling closer to a 125cc, making it a versatile option for various skill levels and off-road terrain.
Digital Format Benefit:
PDF format offers portability, searchability, and the ability to print specific pages for workshop use, superior to aging paper manuals.
Systems Covered:
Engine, Transmission, Fuel System, Ignition System, Cooling System, Exhaust System, Chassis, Suspension, Brakes, Electrical System, Troubleshooting
Page Count:
Estimated 200-300 pages (typical for this era and type of manual)
Manual Type:
Service Repair Manual
Manual Scope:
Factory-level service and repair documentation.
Engine Mechanical:
Detailed disassembly, inspection, assembly, and torque specifications for all engine components (cylinder, piston, crankshaft, connecting rod, valves, camshaft, etc.).
Fuel System:
Carburetor adjustment, cleaning, and overhaul; fuel pump operation (if applicable); fuel tank maintenance.
Ignition System:
Spark plug specifications, ignition timing, stator and CDI unit testing, troubleshooting.
Cooling System:
Radiator maintenance, coolant specifications, water pump inspection and repair, thermostat operation.
Exhaust System:
Muffler and pipe inspection, potential leaks, and replacement.
Transmission And Drivetrain:
Clutch operation, inspection, and adjustment; gearbox disassembly and reassembly; chain and sprocket maintenance.
Chassis And Suspension:
Frame inspection, fork service and seal replacement, rear shock absorber maintenance, linkage lubrication, wheel bearing service.
Brake System:
Brake fluid specifications, caliper and master cylinder overhaul, pad inspection and replacement, bleeding procedures.
Electrical System:
Wiring diagrams, battery maintenance, lighting system troubleshooting, switchgear inspection.
Routine Maintenance:
Oil changes, filter replacements, spark plug checks, air filter cleaning, chain adjustments, lubrication points.
Troubleshooting:
Diagnostic flowcharts and common issue resolution for starting problems, running issues, and performance concerns.
Repair And Rebuild:
Step-by-step instructions for engine rebuilds, carburetor overhauls, suspension servicing, and brake system repairs.
Technical Specifications:
Torque values, clearances, fluid capacities, wiring diagrams, and component dimensions.
Torque Specifications:
Detailed torque specifications for critical fasteners (engine, chassis, suspension) are a key component of the manual.
Wiring Diagrams:
Includes comprehensive electrical system wiring diagrams for troubleshooting and component identification.
Depth:
Comprehensive, covering from basic maintenance to full engine rebuilds and advanced diagnostics. Suitable for both DIY enthusiasts and professional mechanics.
File Format:
PDF (Portable Document Format)
Print Quality:
High-resolution scans for clarity, enabling clear printing of diagrams and text.
Binding Type:
N/A (Digital format)
Paper Type:
N/A (Digital format)
Searchability:
Typically searchable text within the PDF, allowing quick access to specific topics.
Completeness:
This is a comprehensive service and repair manual, intended to cover all aspects of maintenance and repair for the specified model and year.
Engine Type:
Single-cylinder, 2-stroke, liquid-cooled
Displacement:
196 cc (11.96 cubic inches)
Bore X Stroke:
62.5 mm x 65 mm (2.46 in x 2.56 in)
Compression Ratio:
Approx. 8.2:1 (for 200cc 2-stroke, varies slightly)
Horsepower Estimated:
Approximately 30-35 HP (Varies based on tuning and exhaust)
Torque Estimated:
Approximately 20-24 lb-ft (Varies based on tuning and exhaust)
Carburetor:
Keihin PWK 38 carburetor
Fuel Type:
Unleaded gasoline (91-98 octane recommended) mixed with 2-stroke oil
2-Stroke Oil Mix Ratio:
Typically 40:1 or 50:1 with high-quality 2-stroke engine oil (refer to manual for specific recommendation)
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Cooling Method:
Liquid-cooled via radiator and fan
Infotainment Features:
Basic, focused on functionality. Typically includes odometer, trip meter, and essential indicator lights (e.g., neutral, turn signals, oil indicator for premix models).
Assistance Systems:
N/A. Focus is on rider control and mechanical feedback, not electronic rider aids.
Connectivity Features:
None.
Engine Oil Change:
Refer to manual for specific interval, typically every 15-25 hours of operation for 2-stroke.
Air Filter Cleaning:
Frequent checks and cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours).
Spark Plug Check:
Regular inspection and cleaning/replacement as needed, depending on usage.
Chain Lubrication Adjustment:
Lubricate frequently (every 500-1000 km or as needed based on conditions); adjust tension as per manual specs.
Engine Oil Type:
High-quality synthetic 2-stroke motorcycle oil meeting specific API/JASO standards (e.g., JASO FD/FE).
Coolant Type:
Premixed ethylene glycol-based coolant with corrosion inhibitors (typically 50/50 mix).
Brake Fluid Type:
DOT 4 or DOT 5.1 brake fluid (check manual for exact specification).
200Cc 2Stroke Specific:
Common 2-stroke issues include piston ring wear, exhaust port carbon buildup, clutch wear, and carburetor jetting sensitivity to altitude and temperature. The manual addresses these comprehensively.
Ktm Specific 2006:
Potential for wear in the power valve mechanism, suspension seal leaks, and carburetor needle wear over time. Detailed inspection procedures are vital.
Ktm Offroad Legacy:
KTM has a long and successful history in off-road racing, including Motocross and Enduro, dating back to the 1950s. This heritage influences the design and performance of all their off-road models.
Xc W Series:
The XC-W designation signifies KTM's Cross Country racing line, designed for a balance of performance and endurance suitable for various off-road disciplines.
Manufacturing Location:
Austria (KTM's primary manufacturing base)
