Segment:
Off-road motorcycle, Enduro/Cross-Country segment.
Competitors:
Yamaha WR250F, Honda CRF250X, Suzuki RM-Z250, Kawasaki KX250F (though this KTM is a 2-stroke, it competes in the displacement class for off-road performance).
Design Philosophy:
KTM's renowned 'Ready to Race' philosophy, emphasizing lightweight construction, powerful two-stroke engines, and agile handling for competitive off-road use.
Engine Type:
Two-stroke, single-cylinder, liquid-cooled, known for its strong power-to-weight ratio.
Model Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Estimated Page Count:
Varies by specific year and edition, but typically 300-500 pages for a comprehensive service manual.
Type:
Service Repair Workshop Manual
Engine:
Detailed overhaul, troubleshooting, component testing, lubrication, cooling system, fuel system (carburetor tuning and diagnosis), exhaust system.
Transmission:
Clutch operation, gearbox disassembly and assembly, shift mechanism, lubrication, troubleshooting.
Chassis And Suspension:
Front fork service (Öhlins/WP), rear shock absorber service, linkage system, steering head bearings, swingarm maintenance.
Brakes:
Brake system service, hydraulic components, pad replacement, fluid bleeding, caliper maintenance, master cylinder.
Electrical System:
Wiring diagrams, lighting, ignition system, charging system (stator, regulator/rectifier), battery maintenance, troubleshooting electrical faults.
Bodywork And Plastics:
Fairing removal and installation, seat, fuel tank, fenders, general bodywork repair.
Maintenance:
Routine checks, oil changes, filter replacements, chain adjustment, spark plug service, pre-ride inspections.
Troubleshooting:
Diagnostic guides for common problems, symptom-based troubleshooting charts.
Repair:
Step-by-step instructions for component disassembly, repair, and reassembly.
Depth:
Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including detailed torque specifications and component clearances.
Quality:
High-resolution PDF, typically optimized for digital viewing and printing.
Searchability:
Searchable text content allows for quick access to specific information.
Printability:
Designed to be printable, allowing users to create physical copies of sections or the entire manual.
Binding:
N/A (Digital PDF Download)
Paper Type:
N/A (Digital PDF Download)
Type:
Liquid-cooled, 2-stroke, single-cylinder with reed valve induction and PowerJet carburetor system (often Keihin PWK).
Displacement:
Approximately 193 cc (bore x stroke typically around 66 mm x 57.4 mm).
Bore X Stroke:
Approx. 66.0 mm x 57.4 mm
Compression Ratio:
Typically around 12.0:1 to 13.5:1 (subject to specific model year).
Ignition:
Digital electronic ignition (CDI).
Horsepower:
Estimated 40-45 HP (at crankshaft, varies by year and tuning).
Torque:
Estimated 35-40 Nm (at crankshaft, varies by year).
Carburetor:
Keihin PWK 36mm (common) with PowerJet technology for improved high-RPM performance.
Fuel Type:
Unleaded gasoline, minimum 95 octane recommended. Requires 2-stroke oil pre-mix or oil injection system.
System:
Premix fuel/oil or automatic oil injection system (depending on specific model year and region).
Type:
Liquid-cooled via radiator and fan.
Oil Change:
Every 10-15 hours of riding or annually. Use specified 2-stroke engine oil (e.g., Motul 800 2T Factory Line Off Road).
Air Filter Cleaning:
After every few rides, especially in dusty conditions. Use specific foam filter cleaner and oil.
Spark Plug Check:
Every 20-30 hours of riding. Recommended plug: NGK BR9EG or similar.
Chain Lubrication Adjustment:
After every ride or as needed. Check tension every 5-10 hours.
Top End Rebuild:
Recommended every 60-100 hours for optimal performance and reliability, depending on usage and maintenance.
Engine Oil:
2-stroke, high-performance synthetic oil (e.g., Motul, Castrol) for pre-mix or oil injection system. Specific type and ratio for pre-mix will be detailed in the manual.
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors. 50/50 mix with distilled water is typical. Capacity: approx. 0.8-1.0 Liters.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Transmission Oil:
Specific gear oil for the gearbox, e.g., Motul Transoil 10W-40 or equivalent. Capacity: approx. 0.7-0.8 Liters.
Carburetor Tuning:
Can be sensitive to altitude, temperature, and jetting changes. Requires periodic adjustment and cleaning for optimal performance.
Power Valve Maintenance:
The exhaust power valve system requires periodic cleaning and inspection to prevent sticking and ensure proper operation, which affects low-end torque and high-end power delivery.
Clutch Wear:
Clutch plates can wear over time, especially with aggressive riding. Symptoms include slipping. The manual details inspection and replacement procedures.
Suspension Seals:
Like all off-road bikes, fork seals and shock seals can be prone to leaks due to harsh conditions. Regular cleaning of fork stanchions and inspection of seals is recommended.
Origin:
KTM is an Austrian motorcycle manufacturer with a strong heritage in off-road racing (Motocross, Enduro, Dakar Rally).
Development:
The 200 XC represents KTM's continuous development of their two-stroke off-road platform, offering a potent blend of power and agility in the 200cc class. Updates often included suspension improvements, carburetor tuning, and minor chassis revisions over the years.
Manufacturing Location:
Austria
