KTM 200 MXC Engine 1999-2010 Service Repair Manual

Regular price: $16.99
Sale price: $16.99
Regular price
Unit price: per

19 people are viewing this right now

Type: Motorcycle

Vendor:

Sku: 94486

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

Product variants

Description

The 200 MXC is a high-performance, off-road competition motorcycle renowned for its potent 200cc, liquid-cooled, two-stroke engine and agile handling. Manufactured by the Austrian brand, celebrated for its off-road dominance, this model was designed for aggressive riding disciplines such as motocross and enduro. Its engineering emphasizes lightweight construction, featuring a chromoly steel trellis frame, and a powerful engine delivering strong low-to-mid range performance, making it a competitive choice in its class throughout its production years from the late 1990s to 2010. This comprehensive service repair manual covers the 200 MXC from 1999 to 2010, providing essential information for maintenance, repair, and troubleshooting. It details procedures for all major mechanical and electrical systems, including the engine, transmission, clutch, brakes, and suspension. The manual includes scheduled maintenance tasks, step-by-step repair instructions, diagnostic charts for common issues, and technical specifications. Its thorough coverage is intended to assist both novice owners and experienced technicians in keeping the vehicle in optimal condition and ensuring its longevity.

🏷️ Basic Information

Identification

Make:

Model:

200 MXC

Engine Variant:

200cc

Codes

Model Code:

200 MXC (specific internal codes may vary by year and region)

👋 Introduction

Market Position

Segment:

Off-road Enduro / Competition Motorcycle

Competitive Analysis

Competitors:

Competed against models like Yamaha YZ250, Honda CR250R, Suzuki RM250 (in similar displacement classes for performance-oriented dirt bikes), though the 'MXC' designation points specifically to KTM's enduro line.

Key Features

Performance Focus:

Lightweight, agile, potent 2-stroke engine, designed for aggressive off-road riding, motocross, and enduro disciplines.

Engineering:

Renowned KTM engineering for performance and durability in demanding off-road conditions.

📋 Manual Details

Coverage Areas

Applicable Years:

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

Page Count

Estimated Pages:

300-500 (typical for comprehensive service manuals of this era, exact count not provided)

Manual Type

Type:

Service Repair Manual

Language

Language:

English (assumed, common for KTM service manuals)

Format

Format:

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, tuning, troubleshooting, lubrication system, cooling system (if applicable), fuel system (carburetor, fuel pump), ignition system, exhaust system.

Transmission:

Gearbox internal components, clutch operation and adjustment, shift mechanism, lubrication.

Chassis:

Frame inspection and repair, suspension (forks, shock absorber), steering system, wheel bearings, brake system (hydraulic components, pad replacement, bleeding), electrical system (wiring diagrams, lighting, ignition components, charging system).

Procedures Included

Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, spark plug service, chain adjustment, brake pad inspection, general tune-ups.

Repair:

Detailed step-by-step repair procedures for all major mechanical and electrical components. Includes engine rebuild, gearbox overhaul, suspension repair, electrical fault diagnosis.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common operational issues, performance problems, and component failures.

Technical Depth

Depth:

Comprehensive, covering from basic routine maintenance to in-depth engine and component overhauls. Suitable for both DIY mechanics and professional technicians.

📊 Manual Specifications

File Format

File Type:

Searchability:

Searchable text content (typical for high-quality PDF manuals)

Print Quality

Printability:

Printable pages for workshop use

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Quality:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Configuration:

Single-cylinder, 2-stroke

Displacement:

193cc (approximately)

Bore X Stroke:

62.5 mm x 65 mm (typical for 200cc class)

Cooling System:

Liquid-cooled

Ignition:

Digital CDI

Performance

Horsepower:

Approximately 35-40 HP (stock, depending on year and specific tuning)

Torque:

N/A (Specific torque figures not readily available, but known for strong low-to-mid range power)

Fuel System

Carburetor:

Keihin PWK (e.g., 36mm, specific model may vary by year)

Fuel Type:

Unleaded gasoline with appropriate 2-stroke oil premix

Lubrication

Premix Ratio:

Typically 40:1 or 50:1 (refer to manual for exact specification and recommended oil type)

🔧 Transmission

Standard

Type:

6-speed manual

Clutch:

Wet multi-plate clutch

Features

Gearbox Design:

Robust KTM design for durability in off-road conditions.

📐 Dimensions

Exterior

Wheelbase:

Approximately 1445-1470 mm (1470mm is common for this era KTM 200)

Seat Height:

Approximately 950-960 mm

Weights

Dry Weight:

Approximately 95-105 kg

Fuel Tank Capacity:

Approximately 9-11 Liters

🛡️ Safety Features

Ratings

Crash Test Results:

N/A (As it's a competition off-road motorcycle, official crash test ratings are not applicable).

Active Features

Brakes:

Hydraulic disc brakes front and rear. Brembo calipers and rotors were standard on many KTM models of this era, known for excellent stopping power.

Passive Features

Frame Construction:

Chromoly steel trellis frame, providing a balance of strength, rigidity, and light weight.

💡 Technology Features

Infotainment

Features:

N/A (This is a pure competition off-road motorcycle; infotainment systems are not present.)

Driver Assistance

Features:

N/A (No electronic rider aids such as ABS, traction control, etc.)

Connectivity

Features:

N/A (No smart device integration or connectivity features.)

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 10-15 hours of riding (typical for 2-stroke off-road bikes, check manual)

Air Filter Cleaning:

After every significant ride or as needed based on dust conditions.

Spark Plug Service:

Every 20-30 hours of riding, or as needed based on performance.

Top End Rebuild:

Every 80-150 hours of riding (depending on usage and maintenance, piston and ring replacement)

Fluid Specifications

Engine Oil Type:

High-quality 2-stroke synthetic or semi-synthetic oil, meeting JASO FD or API TC standards. Refer to manual for specific KTM recommendations (e.g., Motorex).

Coolant Type:

Ethylene glycol-based antifreeze, 50/50 mix with distilled water. Use a quality coolant suitable for high-performance engines.

Gearbox Oil Type:

SAE 10W/40 or 10W/50 gear oil, API GL-4 or GL-5 rated. Specific KTM recommendation usually SAE 75W/90 (check manual for correct specification and capacity).

Known Issues

Carburetor Tuning:

Can require meticulous jetting and adjustment for optimal performance across different altitudes and temperatures. Manual provides guidance.

Clutch Wear:

Heavy use can lead to premature clutch plate wear; proper adjustment and usage are key.

Power Valve Maintenance:

The exhaust power valve system is critical for 2-stroke performance; it requires regular cleaning and inspection for carbon buildup and proper operation. Manual details this procedure.

Suspension Seals:

Like many off-road bikes of this era, fork and shock seals can require periodic replacement due to the demanding nature of the sport.

📚 Vehicle History

Brand Heritage

Origin:

Austrian manufacturer, KTM is renowned for its off-road motorcycle dominance, particularly in enduro and motocross.

Model Evolution

Development:

The 200 MXC was part of KTM's expanding off-road line-up, offering a potent 2-stroke option that bridged the gap between 125cc and larger displacement machines. It evolved from earlier KTM enduro models.

Production

Manufacturing Location:

Austria (KTM's primary manufacturing base)

Production Period:

Produced from late 1990s through the 2010 model year, with continuous updates to components and tuning.

🏆 Awards & Recognition

Recognitions

Model Specific Awards:

While specific awards for the 200 MXC may not be widely publicized, KTM as a brand consistently received accolades in off-road racing series and rider polls throughout this period for its performance-oriented motorcycles.

Ratings

Industry Reputation:

KTM bikes of this era were highly regarded for their competitive performance, robust construction, and rider-focused ergonomics.