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Introduction
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Market Position
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Motorcycle Segment:
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Entry-level performance motorcycle, often categorized as a sport naked or light sportbike.
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Target Audience:
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Riders seeking accessible performance, agility, and the distinctive KTM riding experience, often as a first larger displacement motorcycle or for urban commuting.
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Competitive Analysis
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Key Competitors:
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Competed against other 200-250cc motorcycles from Japanese and European manufacturers, such as Yamaha YZF-R25, Kawasaki Ninja 250, and Honda CBR250R (depending on regional availability).
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Key Features
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Performance Focus:
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Known for its nimble handling, sporty engine characteristics, and aggressive styling, embodying KTM's 'Ready to Race' philosophy.
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Design Philosophy:
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Compact, lightweight chassis with a focus on rider engagement and agility.
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Manual Details
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Coverage Areas
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Technical Coverage:
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Full repair, maintenance, troubleshooting, and adjustment procedures for the KTM 200 (2000 model year).
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Component Coverage:
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Engine, transmission, fuel system, electrical system, brakes, suspension, chassis, bodywork, and all associated components.
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Page Count
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Estimated Page Count:
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Typically 300-500 pages for a comprehensive factory service manual of this nature.
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Manual Type
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Manual Type:
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Factory Service Repair Manual
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Language
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Language:
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English (assumed based on typical distribution, but not explicitly stated)
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Format
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Format:
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PDF Download
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Manual Coverage
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Systems Covered
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Engine Systems:
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Engine disassembly, assembly, internal component inspection, valve adjustment, piston/cylinder diagnostics, cooling system maintenance, lubrication system service.
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Fuel System:
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Carburetor specifications, cleaning, adjustment, fuel pump operation (if applicable), fuel line routing and inspection.
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Transmission And Drivetrain:
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Clutch operation, disassembly, and adjustment; gearbox inspection and repair; final drive chain maintenance and adjustment.
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Electrical System:
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Wiring diagrams, component testing (ignition, lighting, charging system), starter motor troubleshooting, battery maintenance.
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Brake System:
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Brake pad replacement, caliper service, master cylinder maintenance, brake fluid bleeding and replacement, disc inspection.
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Suspension And Steering:
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Front fork service, rear shock absorber maintenance, steering head bearing adjustment and replacement, wheel bearing inspection.
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Chassis And Bodywork:
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Frame inspection, body panel removal and installation, seat maintenance, handlebar and control adjustments.
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Procedures Included
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Maintenance Procedures:
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Routine servicing, oil changes, filter replacements, chain lubrication, brake adjustments, tire pressure checks.
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Troubleshooting Guides:
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Systematic diagnostic steps for common and uncommon problems, fault code interpretation (if applicable).
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Repair Procedures:
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Detailed, step-by-step instructions for component removal, repair, and reassembly.
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Adjustment Procedures:
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Carburetor synchronization, chain tension adjustment, suspension settings, clutch lever free play.
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Torque Specifications:
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Precise torque values for all critical fasteners, ensuring proper assembly and preventing damage.
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Technical Depth
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Diagnostic Capability:
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Advanced diagnostics for electrical and mechanical systems, enabling identification of root causes of issues.
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Rebuild Capability:
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Comprehensive instructions for complete engine and transmission rebuilds.
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Component Specs:
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Detailed specifications for all major components, including clearances, tolerances, and wear limits.
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Engine Specifications
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Primary Engine
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Engine Type:
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Single-cylinder, four-stroke, liquid-cooled
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Displacement:
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Approximately 199.5 cc (exact displacement for the 2000 model may vary slightly by region or specific variant)
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Bore X Stroke:
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Typical for this era would be around 66 mm x 58 mm, but specific figures require manual confirmation.
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Performance
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Horsepower:
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Estimated 25-30 hp at the crank, exact figures depend on tuning and market.
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Torque:
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Estimated 18-20 Nm at the crank, exact figures depend on tuning and market.
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Fuel System
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Fuel Delivery:
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Carburetor (likely a Mikuni VM30 or similar size)
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Fuel Type:
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Unleaded gasoline, octane rating as specified in the manual (typically 91 RON or higher).
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Cooling System
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Cooling Method:
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Liquid-cooled with radiator and fan.
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Lubrication
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Lubrication System:
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Wet sump lubrication.
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Dimensions
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Exterior
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Length:
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Approximate length will be around 2000mm, specific figures to be confirmed by manual.
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Width:
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Approximate width will be around 750mm, specific figures to be confirmed by manual.
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Height:
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Approximate height will be around 1050mm, specific figures to be confirmed by manual.
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Weights
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Dry Weight:
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Typically in the range of 120-130 kg, specific figure to be confirmed.
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Wet Weight:
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Approximate wet weight would be around 135-145 kg, specific figure to be confirmed.
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Fuel Tank Capacity:
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Around 10-12 liters, specific figure to be confirmed by manual.
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Safety Features
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Ratings
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Safety Certification:
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Meets relevant safety standards for motorcycles of its era, specific certifications depend on market of sale.
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Active Features
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Braking System:
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Disc brakes front and rear. Front typically a single disc, rear a single disc. ABS was generally not standard on this model/era.
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Suspension Performance:
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Designed for agile handling and stability, crucial for rider control.
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Passive Features
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Lighting System:
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Standard headlight, taillight, brake light, and turn signals.
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Ergonomics:
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Designed for an upright and engaged riding position, promoting rider awareness.
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Maintenance
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Service Intervals
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Oil Change Interval:
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Typically every 3,000-5,000 km or annually, refer to manual for exact interval and conditions.
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Valve Adjustment Interval:
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Intervals vary, but typically around 10,000-15,000 km. Manual will specify.
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Chain Maintenance:
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Regular cleaning and lubrication recommended every 500-1000 km, plus tension checks.
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Fluid Specifications
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Engine Oil Type:
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Motorcycle-specific SAE 10W-40 or 10W-50 API SG/SH/SJ or higher. Manual will confirm specific viscosity and API rating.
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Coolant Type:
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Ethylene glycol based coolant with corrosion inhibitors. Manual will specify mix ratio and approved brands.
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Brake Fluid Type:
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DOT 4 brake fluid. Manual will specify.
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Known Issues
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Common Wear Items:
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Brake pads, chain and sprockets, tires, clutch plates, spark plugs are common wear items.
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Potential Electrical Issues:
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Older models may experience issues with stator, rectifier, or wiring harness degradation if not properly maintained. Manual will aid in diagnosis.
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Carburetor Tuning:
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Carburetors can require periodic cleaning and adjustment, especially after periods of non-use. Manual provides precise settings.
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