KTM 200 2002 Factory Service Repair Manual

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The 200, produced in 2002, is a lightweight sport motorcycle designed for agile handling and accessible performance, drawing from a strong off-road racing heritage. This model is positioned as an...

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类型: Motorcycle

斯库: 54381

标签: 200 2002 KTM Misc Motorcycle Motorcycles

产品多属性

Description

The 200, produced in 2002, is a lightweight sport motorcycle designed for agile handling and accessible performance, drawing from a strong off-road racing heritage. This model is positioned as an entry-level performance machine, suitable for new riders, urban commuting, and experienced riders seeking a nimble riding experience. Its engineering emphasizes a lightweight chassis, sporty styling, and reliable performance, making it a popular choice in its segment. The 200 is recognized for its sporty character and the commitment to building high-quality, performance-oriented motorcycles. This Factory Service Repair Manual provides comprehensive English-language guidance for the 200. It covers all essential aspects of the vehicle, including detailed procedures for engine disassembly and assembly, fuel and ignition systems, cooling, exhaust, transmission, drivetrain, brakes, suspension, and the electrical system. The manual also details maintenance schedules, troubleshooting common issues, and specific repair instructions. Its scope extends to chassis and frame, bodywork, and technical specifications, ensuring that owners, mechanics, and technicians have the necessary information to maintain, diagnose, and repair the vehicle effectively.

🏷️ Basic Information

Identification

Make:

Model:

Year:

Codes

Chassis Code:

Not Specified (likely model-specific internal designation)

Engine Code:

Not Specified (likely model-specific internal designation)

👋 Introduction

Market Position

Segment:

Lightweight sport motorcycle, often used for entry-level performance riding and commuting.

Competitive Analysis

Competitors:

Yamaha YZF-R125/MT-125 (though the 200cc class is less common in some markets), Kawasaki Ninja 250R (larger displacement but similar performance intent), Honda CBR250R.

Key Features

Features:

Lightweight chassis, agile handling, sporty styling, accessible performance, KTM's off-road heritage influence.

Target Audience:

New riders, experienced riders seeking a light and nimble machine, urban commuters.

📋 Manual Details

Coverage Areas

Manual Type:

Factory Service Repair Manual

Language:

English

Format:

PDF Download

Page Count

Page Count:

Not specified, but expected to be comprehensive for a factory service manual

📖 Manual Coverage

Systems Covered

Engine:

Complete engine disassembly, assembly, inspection, and troubleshooting for all internal and external components.

Fuel System:

Fuel tank, fuel pump, fuel filter, carburetor (or fuel injection system if applicable), fuel lines, and related components.

Ignition System:

Ignition coil, spark plug, CDI unit, wiring, and timing adjustments.

Cooling System:

Radiator, coolant, water pump, thermostat, hoses, and fan (if equipped).

Exhaust System:

Exhaust manifold, pipes, muffler, and catalytic converter (if applicable).

Transmission:

Gearbox, clutch system, shift mechanism, and lubrication.

Drivetrain:

Chain, sprockets, swingarm, rear suspension linkage, and wheel bearings.

Brakes:

Front and rear brake systems (hydraulic or cable), master cylinders, calipers, brake pads, brake discs, brake lines, and bleeding procedures.

Suspension:

Front forks (damping, seals, oil levels), rear shock absorber, and spring pre-load adjustments.

Electrical System:

Battery, charging system (stator, regulator/rectifier), starter motor, lighting system (headlight, taillight, indicators), horn, wiring diagrams, fuses, and relays.

Chassis And Frame:

Frame inspection, steering head bearings, and general chassis components.

Bodywork And Trim:

Fairings, seat, fenders, handlebars, and other body panels.

Procedures Included

Maintenance:

Scheduled maintenance (oil changes, filter replacements, chain adjustment, spark plug replacement, air filter cleaning/replacement, brake checks).

Troubleshooting:

Diagnostic procedures for common problems, fault finding based on symptoms.

Repair:

Step-by-step repair instructions for all major and minor components.

Disassembly And Assembly:

Detailed instructions for taking apart and reassembling various systems and components.

Adjustments:

Carburetor synchronization, clutch lever free play, brake lever free play, suspension settings.

Technical Depth

Depth:

Comprehensive, covering everything from basic maintenance to complete engine overhauls and advanced diagnostics.

Diagnostic Codes:

Likely includes diagnostic trouble codes (DTCs) if the model is equipped with electronic diagnostics.

📊 Manual Specifications

File Format

File Format:

Searchable Text:

Typically PDF manuals are text-searchable, allowing for quick keyword lookup.

Print Quality:

High-resolution for clear diagrams, illustrations, and text. Printable.

Binding Type

Binding Type:

N/A (Digital PDF download)

Paper Type

Paper Type:

N/A (Digital PDF download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Four-stroke, single-cylinder (likely Liquid-cooled, DOHC, 4 valves based on common KTM 200 configurations)

Displacement:

199.5 cc (This is a common displacement for KTM 200 models)

Bore X Stroke:

Typically around 72 mm x 49 mm for this displacement.

Performance

Horsepower:

Approximately 25-26 HP (specific to the 2002 model, which might differ slightly from later iterations).

Torque:

Around 19-20 Nm (Newton-meters).

Fuel System

Fuel Delivery:

Likely Carbureted (Mikuni VM26 or similar) for a 2002 model, though some regional variants might have seen early fuel injection.

Fuel Type:

Unleaded gasoline (RON 95 recommended).

Lubrication

Oil Type:

JASO MA certified 10W/40 or 15W/50 motorcycle synthetic or semi-synthetic oil.

Oil Capacity:

Approx. 1.0-1.2 liters without filter change, 1.2-1.4 liters with filter change.

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh gearbox.

Optional

Optional Transmission:

N/A (Typically a single transmission option for this model).

Features

Clutch Type:

Wet multi-disc clutch, operated by cable.

Final Drive:

Chain drive (DID or similar quality, 520 pitch).

📐 Dimensions

Exterior

Length:

Approximately 2000 mm.

Width:

Approximately 740 mm (without mirrors).

Height:

Approximately 1070 mm (seat height may vary).

Wheelbase:

Approximately 1350 mm.

Ground Clearance:

Around 150-170 mm.

Weights

Dry Weight:

Approximately 130-140 kg (depending on specific equipment).

Curb Weight:

Not explicitly stated for this year but would include fluids.

Fuel Capacity:

Approximately 11-12 liters.

🛡️ Safety Features

Ratings

Safety Ratings:

N/A (Motorcycles are not typically subject to the same crash testing ratings as cars).

Active Features

Braking System:

Dual piston front caliper with disc, single piston rear caliper with disc. ABS was not common on this class of motorcycle in 2002.

Lighting:

Halogen headlight, LED taillight (typical), incandescent turn signals.

Passive Features

Frame Construction:

Trellis frame (steel) for rigidity and light weight, typical of KTM.

Tires:

Front: 110/70-17, Rear: 150/60-17 (common sizes).

Wheel Type:

Cast aluminum alloy wheels.

💡 Technology Features

Infotainment

Infotainment System:

Basic analog/digital instrument cluster displaying speed, RPM, odometer, trip meter, fuel level, and warning lights. No advanced infotainment features like Bluetooth or navigation.

Driver Assistance

Driver Assistance:

N/A for motorcycles of this era. ABS was not standard.

Connectivity

Connectivity:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5,000 - 7,500 km or annually, whichever comes first.

Oil Filter Change:

Every oil change.

Air Filter Cleaning:

Every 3,000 - 5,000 km, replace if damaged or excessively dirty.

Spark Plug Replacement:

Every 10,000 - 12,000 km or as specified by the manual.

Chain Lubrication Adjustment:

Lubricate every 500 km, adjust slack as needed (typically 20-30 mm).

Valve Clearance Check:

Every 10,000 - 15,000 km.

Fluid Specifications

Brake Fluid:

DOT 4 or DOT 5.1.

Coolant:

Mixture of distilled water and ethylene glycol-based antifreeze (e.g., Motorex Coolant M5.0).

Known Issues

Common Issues:

Potential for premature wear on certain engine components if not maintained properly, clutch lever adjustment may be needed periodically, occasional electrical gremlins if wiring is damaged.

Maintenance Importance:

Regular maintenance is crucial for preserving performance and longevity, especially given its sporty nature.

📚 Vehicle History

Brand Heritage

Brand Origin:

KTM is an Austrian motorcycle manufacturer with a strong heritage in off-road racing (motocross, enduro, Dakar Rally).

Model Evolution

Model Lineage:

The 200 Duke/RC 200 series represents KTM's entry into the smaller displacement street-focused segment, leveraging their expertise in performance and design.

Production

Manufacturing Location:

Likely manufactured in Austria or India through a partnership for certain markets.

🏆 Awards & Recognition

Recognitions

Awards:

While specific awards for the 2002 model are not widely publicized, KTM generally receives accolades for its performance-oriented, lightweight, and well-engineered motorcycles across its range.