KTM 200 XC 1999-2010 Workshop Service Manual for Repair

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🏷️ Basic Information Identification Make: KTM Model: 200 XC Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Engine Variant Covered: 200cc (specific variant...

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Type: Motorcycle

Vendor:

Sku: 80976

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

Product variants

Description

🏷️ Basic Information

Identification

Make:

Model:

200 XC

Model Years Covered:

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

Engine Variant Covered:

200cc (specific variant details to be confirmed via manual content)

👋 Introduction

Market Position

Segment:

Off-Road Competition (XC - Cross Country)

Category:

Performance Off-Road Motorcycle

Competitive Analysis

Competitors:

Husqvarna WR250, Gas Gas EC250, Beta RR250, Yamaha YZ250 (depending on specific year comparisons, though 200cc is a niche)

Key Features

Vehicle Focus:

Lightweight, agile, potent 2-stroke performance for off-road racing and aggressive trail riding.

Manual Benefit:

Enables owners and technicians to maintain peak performance, diagnose issues efficiently, and perform all necessary repairs.

📋 Manual Details

Coverage Areas

Primary Coverage:

Workshop Service and Repair

Target Audience:

KTM Technicians, DIY Mechanics, Enthusiasts

Page Count

Total Pages:

Manual Type

Type:

Workshop Service Manual

Language

Language:

English (presumed, standard for KTM technical documentation)

Format

Format:

PDF (Digital Download)

📖 Manual Coverage

Systems Covered

Engine:

Complete overhaul, tuning, carburetor adjustment, ignition system, cooling system (if applicable), lubrication system.

Transmission:

Clutch operation, gearbox disassembly and reassembly, shift mechanism, lubrication.

Chassis:

Frame inspection and repair, suspension (forks, rear shock), steering system, wheels and hubs.

Brakes:

Hydraulic brake system (front and rear calipers, master cylinders, lines), pad replacement, fluid bleeding, rotor inspection.

Electrical:

Wiring diagrams, lighting system, ignition system components, battery maintenance, charging system (stator, rectifier).

Bodywork:

Fairing removal and installation, seat, fuel tank, fenders.

Controls:

Throttle assembly, clutch lever, brake lever, footpegs, handlebars.

Procedures Included

Maintenance:

Regular service intervals, lubrication points, filter changes, spark plug replacement, chain adjustment.

Repair:

Step-by-step instructions for all major component repairs and replacements.

Troubleshooting:

Diagnostic flowcharts and common problem identification for various systems.

Disassembly Reassembly:

Detailed procedures for component removal and reinstallation.

Technical Depth

Depth:

Comprehensive: Covers routine maintenance, advanced diagnostics, and complete engine/component rebuilds.

📊 Manual Specifications

File Format

File Type:

Searchability:

Text-searchable PDF (likely, typical for professional manuals)

Print Quality

Quality:

High-resolution (expected for professional workshop manuals, suitable for printing)

Binding Type

Type:

N/A (Digital Download)

Paper Type

Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Type:

2-Stroke, Single Cylinder

Displacement:

193cc (approximate for KTM 200 models of this era)

Bore X Stroke:

62.5 mm x 64 mm (typical for KTM 200s)

Cooling System:

Liquid-Cooled

Performance

Horsepower:

Approximately 35-40 HP (estimate based on era and displacement)

Torque:

Not readily available for specific model year, but expected to provide strong mid-range power.

Fuel System

Carburetor:

Keihin PWK 36 (typical for KTM 200 XC of this period)

Fuel Type:

Unleaded Gasoline (91 octane or higher recommended)

Oil Mixture:

Pre-mix (typically 50:1 or 40:1 with high-quality 2-stroke oil, refer to manual for exact specification)

🔧 Transmission

Standard

Type:

6-Speed Manual

Clutch:

Wet Multi-Plate Clutch

Features

Gear Ratios:

Specific gear ratios are detailed within the workshop manual.

Final Drive:

Chain Drive

📐 Dimensions

Exterior

Wheelbase:

Approximately 1460 mm (57.5 inches) - subject to variation by year.

Weights

Dry Weight:

Approximately 100-105 kg (220-231 lbs) - subject to variation by year.

Fuel Capacity:

Approximately 8-10 Liters (2.1-2.6 US Gallons) - subject to variation by year.

🛡️ Safety Features

Ratings

Crash Test Ratings:

N/A (Motorcycles typically do not undergo standardized crash testing like passenger cars).

Active Features

Braking:

Hydraulic Disc Brakes (Front and Rear)

Passive Features

Frame Construction:

Chromoly Steel Trellis Frame (characteristic of KTM off-road bikes)

💡 Technology Features

Infotainment

Features:

N/A (Basic off-road motorcycle, focus is on performance and durability, not electronics beyond essential functions).

Driver Assistance

Features:

Connectivity

Features:

🔧 Maintenance

Service Intervals

Oil Change:

Refer to manual for specific interval based on riding conditions; typically every 10-15 hours of hard use or annually.

Air Filter Cleaning:

Frequent cleaning recommended for off-road use; every 5-10 hours or as needed.

Spark Plug Replacement:

Refer to manual; typically every 20-40 hours of operation.

Fluid Specifications

Engine Oil Transmission Oil:

KTM specifies specific gearbox oil (e.g., Motorex Gear Oil 80W) and 2-stroke premix oil. Manual will list exact specifications.

Coolant:

Ethylene Glycol Based Coolant (50/50 mix with distilled water) - specific type detailed in manual.

Brake Fluid:

DOT 4 Hydraulic Brake Fluid (refer to manual for precise type and brand recommendations).

Known Issues

Common Wear Items:

Clutch plates, piston rings, wheel bearings, steering head bearings, suspension seals.

Potential Failures:

Carburetor jetting issues, ignition coil failure, exhaust power valve sticking (with improper maintenance).

Parts Information

Part Numbers:

The manual will contain detailed part numbers for all components and consumables.

📚 Vehicle History

Brand Heritage

Heritage:

KTM AG is an Austrian manufacturer renowned for its off-road motorcycles, known for performance and racing prowess.

Model Evolution

Development:

The 200 XC models represent KTM's commitment to the competitive off-road market, offering a potent blend of power and agility in a 200cc package.

Production

Covering a significant decade of the 200 XC's production history.

🏆 Awards & Recognition

Recognitions

Brand Recognition:

KTM is consistently recognized for its dominance in off-road racing disciplines (Motocross, Enduro, Rally).

Ratings

Model Performance:

The 200 XC series is generally lauded for its strong power-to-weight ratio and aggressive off-road capabilities.