The 2006 KTM 200 XC is a specialized off-road motorcycle designed for competitive cross-country riding. Building on KTM's strong heritage in off-road performance, this model offers agile handling and a potent 196 cc liquid-cooled, two-stroke engine, delivering approximately 35-40 horsepower. Its lightweight construction, around 98 kg (216 lbs) dry weight, and robust chromium-molybdenum steel frame make it ideal for enthusiasts seeking a competitive edge in motocross or enduro environments. The 200 XC features a 6-speed manual transmission with a hydraulically actuated wet multi-plate clutch and is equipped with hydraulic disc brakes for reliable stopping power. This comprehensive factory service repair manual provides detailed instructions and specifications for maintaining and repairing the 2006 KTM 200 XC. It covers all essential systems, including the engine, transmission, fuel, ignition, cooling, exhaust, clutch, brakes, suspension, wheels, and electrical components. The manual offers step-by-step procedures for routine maintenance, component rebuilds, and troubleshooting common issues. With its in-depth technical information, including torque values, fluid specifications, and wiring diagrams, this manual serves as an indispensable resource for owners, mechanics, and technicians dedicated to preserving the performance and longevity of their KTM 200 XC. 🏷️ Basic Information Identification Make: KTM Model: 200 XC Year: 2006 Codes Chassis Code: Not explicitly provided, but typically starts with 'VBK' for KTM motorcycles 👋 Introduction Market Position Segment: Off-road/Motocross/Enduro Lightweight Competition Competitive Analysis Competitors: Yamaha YZ250F, Honda CRF250R, Kawasaki KX250F, Suzuki RM-Z250 (though 200cc is a niche) Key Features Performance Focus: Agile handling, powerful (for its class) two-stroke engine, competitive off-road performance. Target Audience: Enthusiasts seeking a lightweight, competitive off-road motorcycle for racing or trail riding. 📋 Manual Details Coverage Areas Coverage: Complete Factory Service Repair Page Count Pages: Hundreds (Exact count not specified, but implies comprehensive) Manual Type Type: Factory Service Repair Manual Language Language: English (Assumed for factory manuals targeting primary markets) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, troubleshooting, and component specifications. Transmission: Gearbox inspection, maintenance, repair, and shift mechanism. Fuel System: Carburetor tuning, cleaning, and component replacement; fuel tank, lines, and filter. Ignition System: Ignition coil, CDI unit, spark plug specifications, and troubleshooting. Cooling System: Radiator, coolant, hoses, water pump inspection and replacement. Exhaust System: Exhaust pipe, silencer inspection and replacement. Clutch: Clutch operation, adjustment, and component replacement (plates, springs). Brakes: Front and rear brake systems, caliper servicing, pad replacement, fluid bleeding, master cylinder. Suspension: Front fork (WP Suspension) disassembly, service, oil levels, and rear shock absorber. Wheels And Tires: Wheel bearing maintenance, spoke tension, tire pressure recommendations, and replacement. Electrical System: Wiring diagrams, lighting, battery maintenance, starter motor, and charging system. Frame And Bodywork: Frame inspection, subframe, plastic components, seat, and handlebar. Procedures Included Maintenance: Regular servicing, lubrication, filter changes, adjustments. Troubleshooting: Diagnostic guides for common issues and faults. Repair: Step-by-step instructions for component repairs and replacements. Rebuilds: Comprehensive engine and gearbox rebuild procedures. Specifications: Torque values, clearances, fluid capacities, and technical data. Technical Depth Depth: Complete factory-level detail, suitable for professional mechanics and experienced DIY enthusiasts. 📊 Manual Specifications File Format Format: PDF Print Quality Printability: High-resolution, designed for clear printing of individual pages or the entire manual. Binding Type Binding: N/A (Digital PDF) Paper Type Paper: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine Type: 2-Stroke, Single-Cylinder Displacement: 196 cc (approximate) Bore X Stroke: Not explicitly provided, but typical for this era's KTM 200s would be around 64mm x 62.5mm Cooling: Liquid-Cooled Performance Horsepower: Estimated 35-40 HP (typical for this class and era) Torque: Not explicitly provided, but strong mid-range power delivery. Fuel System Carburetor: Keihin PWK 36mm (common for KTM models of this era) Fuel Type: Unleaded gasoline with appropriate 2-stroke oil premix Ignition System Ignition: Digital CDI Starting System Starter: Kick Starter 🔧 Transmission Standard Type: 6-Speed Manual Optional Options: N/A (Typically single transmission option for competition models) Features Clutch: Hydraulically actuated wet multi-plate clutch Final Drive: Chain driven 📐 Dimensions Exterior Wheelbase: Approximately 1445 mm (56.9 inches) (typical for 200 XC) Seat Height: Approximately 925 mm (36.4 inches) (typical for 200 XC) Weights Dry Weight: Approximately 98 kg (216 lbs) (typical for 200 XC) Fuel Capacity: Approximately 8.5 Liters (2.25 Gallons) (typical for 200 XC) 🛡️ Safety Features Ratings Safety Standards: N/A (Competition off-road motorcycles are not typically safety rated in the same way as street vehicles) Active Features Braking System: Hydraulic disc brakes front and rear (Brembo components common) Passive Features Frame Design: Chromium-molybdenum steel, central double-cradle frame. 💡 Technology Features Infotainment Features: N/A (Pure competition off-road motorcycle, no infotainment systems) Driver Assistance Features: N/A (No electronic rider aids typically found on competition off-road bikes) Connectivity Features: N/A Performance Enhancement Engine Management: Basic CDI ignition with no advanced electronic fuel injection or engine mapping. 🔧 Maintenance Service Intervals Oil Change: Every 10-15 hours of riding or annually; gearbox oil every 20-30 hours. Air Filter:...