Segment:
Lightweight, high-performance off-road motorcycle (Enduro/Cross Country).
Competitors General:
Competes with other small-displacement 2-stroke off-road bikes from brands like Yamaha (YZ250), Honda (CR250), Suzuki (RM250), and Kawasaki (KX250) in their respective classes, though often positioned for specific enduro applications.
Engine Type:
Compact 2-stroke engine known for its snappy power delivery and light weight.
Chassis Design:
Austrian-engineered chassis, typically featuring WP suspension and a strong chromoly steel frame, emphasizing agility and handling.
Offroad Capability:
Designed specifically for off-road riding, with long-travel suspension, knobby tires, and a durable build.
Covered Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Estimated Page Count:
500+
Manual Type:
Factory Service Repair Manual
Engine:
Complete engine disassembly, inspection, repair, and reassembly for the 2-stroke LC2 engine.
Transmission:
Gearbox, clutch, and shift mechanism maintenance and repair.
Chassis:
Frame, swingarm, suspension (forks and shock), and steering components.
Electrical System:
Ignition, lighting, charging system, wiring diagrams, and component testing.
Fuel System:
Carburetor (Keihin PWK likely), fuel tank, petcock, and fuel lines.
Cooling System:
Radiator, coolant hoses, and thermostat (if applicable).
Brakes:
Hydraulic front and rear brake systems, including calipers, master cylinders, lines, and bleeding procedures.
Wheels Tires:
Wheel bearing maintenance, spoke tensioning, and tire changing.
Bodywork:
Fairings, seat, fenders, and plastics removal and installation.
Preventive Maintenance:
Regular service intervals for oil changes, filter replacements, chain adjustment, and bolt torque checks.
Troubleshooting:
Diagnostic guides for common problems related to engine performance, electrical issues, and starting difficulties.
Repair Procedures:
Step-by-step instructions for component replacement and overhaul.
Engine Rebuild:
Detailed instructions for top-end (piston, rings, cylinder) and bottom-end (crankshaft, bearings) rebuilds.
Suspension Setup:
Information on adjusting suspension sag, compression, and rebound damping.
Carburetor Tuning:
Jetting recommendations, idle speed adjustment, and float height setting.
Wiring Diagrams:
Comprehensive and clearly illustrated wiring schematics.
Depth:
Comprehensive, covering everything from routine maintenance to complete engine and chassis overhauls, with detailed diagnostic procedures.
Engine Type:
2-stroke, liquid-cooled
Bore X Stroke:
62.5 mm x 65 mm (typical for this era LC2)
Compression Ratio:
Approx. 8.5:1 (typical, may vary by year/tune)
Horsepower:
Approximately 40-45 HP (estimated, peak output)
Torque:
Approximately 20-22 lb-ft (estimated)
Carburetor Type:
Keihin PWK 38mm (common for this model)
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix (typically 40:1 or 50:1 ratio, consult manual)
Oil Type:
High-quality 2-stroke synthetic or semi-synthetic engine oil.
Transmission Type:
6-speed constant mesh
Optional Transmissions:
N/A (standard manual transmission)
Clutch Type:
Hydraulic, multi-plate wet clutch
Final Drive:
Chain drive (520 pitch common)
Gear Ratios:
Specific gear ratios will be detailed within the manual.
Transmission Fluid:
Specialized gearbox oil (e.g., Motorex Gear Oil 75W/80 or equivalent, consult manual for specific KTM recommendation).
Length:
Variable, but typically around 83 inches (2100 mm).
Width:
Variable, but typically around 32 inches (820 mm) at handlebars.
Height:
Variable, but typically around 49 inches (1250 mm) at seat height.
Dry Weight:
Approximately 215-225 lbs (98-102 kg)
Wet Weight:
Approximately 235-250 lbs (107-113 kg)
Cargo Capacity:
N/A (motorcycle designed for off-road performance, not cargo)
Safety Ratings:
Not applicable in the traditional automotive sense; designed for off-road safety and rider control.
Braking System:
Powerful hydraulic disc brakes front and rear for responsive stopping power.
Suspension:
Long-travel, adjustable WP suspension provides excellent control and absorbency over rough terrain.
Ergonomics:
Designed for rider comfort and control during demanding off-road use.
Frame Construction:
Strong chromoly steel trellis frame for rigidity and impact resistance.
Handguards:
Often included as standard or easily fitted to protect hands from impacts and debris.
Infotainment Systems:
N/A (motorcycle focused on performance, no infotainment systems)
Driver Assistance Features:
N/A (no electronic driver assistance features)
Connectivity Features:
N/A
Power Valve:
Features a mechanical power valve system for optimized power delivery across the rev range, requiring proper maintenance and adjustment.
Suspension Brand:
WP Suspension (likely closed-cartridge forks and PDS or linkage-based rear shock).
Oil Change Engine:
Every 10-15 hours of riding or annually, whichever comes first. (Consult manual for specific recommendations).
Air Filter Cleaning:
After every few rides, or more frequently in dusty conditions.
Chain Adjustment:
Check and adjust tension every 5-10 hours of riding.
Spark Plug Inspection:
Every 20-30 hours of riding.
Top End Rebuild:
Varies greatly based on usage and maintenance, typically 60-100 hours for piston/rings, 100-200+ hours for crankshaft.
Engine Oil Type:
2-stroke engine oil (e.g., Motorex Power Synt 2T, Castrol TTS, or equivalent).
Transmission Oil Type:
Gearbox oil (e.g., Motorex Gear Oil 75W/80, Spectro 80W/90 or equivalent).
Coolant Type:
Ethylene glycol-based coolant (50/50 mix with distilled water).
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Issues General:
Wear and tear on clutch plates, power valve operation, carburetor jetting sensitivity to altitude/temperature, typical 2-stroke maintenance requirements (e.g., top-end rebuilds).
Maintenance Importance:
Due to the high-performance nature of 2-stroke engines, adherence to maintenance schedules and using high-quality lubricants is critical for longevity and performance.
Ktm Heritage:
KTM has a long and successful history in off-road motorsports, known for producing high-performance, race-bred motorcycles.
200 Xc-W Evolution:
The 200 XC-W built upon KTM's expertise in smaller displacement 2-stroke engines, offering a balance of power and handling that appealed to riders seeking agility for technical terrain and enduro racing.
Manufacturing Location:
Austria (primarily)
