🏷️ Basic Information

Make:

KTM

Model:

200 XC-W

Years Covered:

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

Product Type:

Service Repair Workshop Manual

Format:

PDF Download

👋 Introduction

Vehicle Segment:

High-performance off-road motorcycle, specifically a lightweight enduro/cross-country model.

Key Competitors Era:

Competed against models from brands like Yamaha (YZ series), Honda (CRF series), Suzuki (RM series), Kawasaki (KX series), Husqvarna, and Sherco in the lightweight off-road segment.

Design Philosophy:

Known for KTM's 'Ready to Race' philosophy, emphasizing lightweight construction, agile handling, and potent two-stroke performance.

Intended User:

Enthusiast riders and racers seeking a nimble and powerful off-road machine for competition and aggressive trail riding.

📋 Manual Details

Comprehensive Coverage:

Full service, repair, and diagnostic information for the specified KTM 200 XC-W models.

Estimated Pages:

300-400 (typical for comprehensive workshop manuals of this era, specific count not provided in product data)

Type:

Workshop Manual / Service Manual / Repair Manual

Language:

English (presumed, standard for major market manuals)

Digital Format:

Searchable PDF

📖 Manual Coverage

Engine Mechanical:

Engine disassembly, inspection, assembly, timing, valve adjustment, piston and cylinder work, crankshaft and connecting rod service.

Engine Electrical:

Ignition system, stator, CDI unit, spark plug diagnosis, wiring diagrams, charging system.

Fuel System:

Carburetor tuning and rebuilding (likely Keihin or Mikuni), fuel tank, fuel lines, petcock operation.

Transmission Drivetrain:

Clutch operation and adjustment, gearbox disassembly and reassembly, chain and sprockets.

Suspension:

Front fork (WP Suspension) disassembly, servicing, oil changes, seal replacement, rear shock absorber servicing, linkage maintenance.

Brakes:

Front and rear brake system servicing, caliper overhaul, master cylinder maintenance, bleeding procedures, pad replacement.

Cooling System:

Radiator, coolant hoses, water pump, coolant replacement and bleeding (if applicable).

Exhaust System:

Exhaust pipe and silencer inspection and maintenance.

Wheels Tires:

Wheel bearing service, spoke tensioning, tire changes.

Chassis Frame:

Frame inspection, steering head bearing service.

Electrical System General:

Lighting, horn, battery maintenance, wiring harness inspection.

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, tire pressure checks.

Diagnostic Troubleshooting:

Step-by-step troubleshooting guides for common performance issues, starting problems, electrical faults.

Major Repairs:

Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs.

Component Rebuilding:

Detailed instructions for rebuilding carburetors, water pumps, brake calipers, and other key components.

Technical Specifications Data:

Torque values for critical fasteners, engine clearances, fluid capacities, electrical specifications.

Wiring Diagrams:

Comprehensive electrical wiring diagrams for easy fault finding and system understanding.

Depth Level:

Comprehensive and detailed, suitable for both experienced mechanics and diligent DIY owners.

Diagnostic Capabilities:

Advanced diagnostic procedures focusing on identifying root causes of malfunctions.

Rebuild Instructions:

Detailed, step-by-step instructions for complete engine and major component rebuilds.

📊 Manual Specifications

File Type:

PDF

Image Resolution:

High-resolution (assumed for clear diagrams and text)

Binding:

N/A (Digital Download)

Paper Quality:

N/A (Digital Download)

Text Search:

Searchable text for quick information retrieval.

Printable Pages:

Printable pages for offline use or referencing during repairs.

⚙️ Engine Specifications

Engine Type:

2-stroke, liquid-cooled

Displacement:

193 cc (approximate, exact for specific model years may vary slightly)

Bore X Stroke:

62.5 mm x 64 mm (typical for this displacement)

Carburetion:

Keihin PWK 36 (common for this generation XC-W)

Horsepower:

Approx. 35-40 HP (estimated, varies by year and specific tuning)

Torque:

Approx. 24-27 Nm (estimated)

Fuel Type:

Unleaded gasoline with 2-stroke oil pre-mix (ratio specified in manual)

Fuel Delivery:

Carburetor

🔧 Transmission

Transmission Type:

6-speed constant mesh

Clutch:

Wet multi-disc clutch, hydraulically operated

Gear Ratios:

Specific gear ratios will be detailed within the manual.

Final Drive:

Chain drive

📐 Dimensions

Wheelbase:

Approximately 1450-1480 mm (varies by year)

Dry Weight:

Approximately 98-102 kg (varies by year and equipment)

Fuel Tank Capacity:

Approximately 8-10 liters (varies by year)

🛡️ Safety Features

Safety Features Focus:

Primarily focused on rider control and braking performance for off-road conditions. No formal crash ratings apply to this type of vehicle.

Braking System:

Hydraulic disc brakes, front and rear. Brembo calipers often utilized.

Suspension Performance:

WP Suspension components designed for optimal control and absorption of off-road terrain.

💡 Technology Features

Infotainment System:

N/A (Performance-oriented off-road motorcycle, no infotainment features).

Assistance Features:

N/A (No electronic rider aids like ABS or traction control are typically found on these models).

Connectivity Features:

N/A

🔧 Maintenance

Oil Change Interval:

Recommended every 10-20 hours of riding or annually, depending on severity of use. Specifics in manual.

Air Filter Cleaning:

Recommended after every few rides, or more frequently in dusty conditions.

Spark Plug Inspection:

Recommended at 20-hour intervals, replacement as needed.

Chain Maintenance:

Lubricate and adjust chain tension every 5-10 hours of riding.

Engine Oil Type:

Specific 2-stroke engine oil meeting KTM specifications (e.g., Motorex Cross Power 2T). Manual will specify grade.

Transmission Oil:

Specific transmission oil for wet clutches (e.g., Motorex Gear Oil 10W/40 or SAE 80).

Coolant:

Water-glycol mixture (50/50) with corrosion inhibitors. Manual specifies type and capacity.

Fork Oil:

Specific suspension fluid (e.g., WP Suspension Fluid) with specified viscosity and quantity per fork leg. Typically SAE 5W or 5W-2.5W.

Common Wear Items:

Piston rings, piston, clutch plates, wheel bearings, fork seals, chain and sprockets.

Carburetor Tuning:

May require periodic re-jetting or cleaning due to fuel variations or wear.

Power Valve Maintenance:

The exhaust power valve mechanism can accumulate carbon and require cleaning for optimal performance.

📚 Vehicle History

Ktm Offroad Legacy:

KTM has a long and storied history in off-road motorsports, consistently producing highly competitive and technologically advanced dirt bikes.

Xcw Series Significance:

The XC-W designation signifies KTM's cross-country racing focus, balancing lightweight agility with the power and endurance needed for long-distance off-road events. The 200cc engine offered a potent combination of torque and high-revving power in a lightweight package.

Manufacturing Origin:

Austria (primarily)

🏆 Awards & Recognition

Offroad Racing Success:

KTM models, including the XC-W line, have a strong track record of success in various off-road racing disciplines such as Enduro and Cross-Country. While specific awards for the 200 XC-W aren't listed in product data, its lineage is synonymous with performance and winning.