The 200 EXC is a high-performance, 2-stroke Enduro motorcycle renowned for its potent power delivery and agile handling. Produced between 1999 and 2006, this Austrian-engineered machine is designed for demanding off-road conditions, offering a compelling blend of manageable weight and robust performance. Its liquid-cooled, single-cylinder engine, typically featuring a power valve system and a 6-speed transmission, provides exhilarating acceleration and versatility for various riding disciplines. With a focus on rider engagement and off-road capability, the 200 EXC has carved out a significant niche among enthusiasts seeking a competitive and capable Enduro experience. This comprehensive Service Repair Manual provides essential information for the maintenance, repair, and troubleshooting of your 200 EXC motorcycle. It covers critical areas such as engine service, including top-end and bottom-end rebuilds, transmission components, and the electrical system. Detailed procedures for routine maintenance, carburetor tuning, clutch overhauls, and common issue diagnosis are included, along with specific technical specifications, fluid recommendations, and torque values. This manual is an indispensable resource for owners and technicians aiming to preserve the optimal performance and longevity of their 200 EXC. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC Model Variant: 2-stroke Enduro Motorcycle Generation Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Code Range: Likely includes specific chassis codes for each model year, but not explicitly stated in product info. 👋 Introduction Market Position Segment: Performance Off-Road Motorcycle (Enduro/Motocross) Target Audience: Owners and mechanics of KTM 200 EXC motorcycles requiring detailed repair and maintenance information. Competitive Analysis Competitors Of Vehicle: Other 125-250cc 2-stroke off-road bikes from brands like Husqvarna, Yamaha (YZ series), Honda (CR series), Suzuki (RM series), Kawasaki (KX series). Key Features Of Vehicle Engine Type: 2-stroke, liquid-cooled, single-cylinder engine known for its potent power delivery and lightweight design. Suspension: Typically equipped with high-quality WP suspension components offering excellent adjustability and performance for off-road use. Key Features Of Manual Utility: Essential resource for DIY maintenance, repair, and troubleshooting, enabling owners to keep their motorcycles in optimal condition and reduce reliance on professional services. 📋 Manual Details Coverage Areas Primary Focus: Engine Service and Repair Additional Coverage: Likely includes sections on routine maintenance, troubleshooting, and potentially basic chassis adjustments related to the engine. Page Count Estimated Page Count: N/A (PDF format, exact page count not specified in product info) Manual Type Type: Service Repair Manual Language Language: English (Assumed based on typical market) Format Format: PDF 📖 Manual Coverage Systems Covered Engine Components: Cylinder, Piston, Crankshaft, Connecting Rod, Crankcase, Cylinder Head, Valves, Ignition System (CDI), Carburetor (likely Keihin PWK), Exhaust System, Cooling System (liquid-cooled), Lubrication System (pre-mix or separate oil injection) Transmission Components: Gearbox Internals, Clutch System (hydraulic or cable operated), Shift Mechanism, Gear Ratios (specifics depend on manual content) Electrical System: Wiring Diagrams (likely focused on engine-related circuits), Ignition Timing, Alternator, Battery Charging System Procedures Included Routine Maintenance: Oil Changes (if applicable for gearbox), Spark Plug Replacement, Air Filter Cleaning/Replacement, Chain Adjustment, Valve Clearance Check/Adjustment (if applicable, though 2-strokes typically don't have them in the traditional sense, may refer to exhaust port timing adjustments), Carburetor Cleaning and Tuning Major Repairs: Top-End Rebuild (Piston, Rings, Cylinder), Bottom-End Rebuild (Crankshaft, Bearings, Seals), Clutch Overhaul, Transmission Rebuild, Ignition System Troubleshooting and Repair, Carburetor Overhaul Troubleshooting: Diagnostic Procedures for Common Issues (e.g., starting problems, poor running, misfiring), Fault Finding Charts, Diagnostic Codes (if applicable) Technical Depth Depth: Comprehensive (Expected to cover from basic maintenance to complete engine and gearbox overhaul, including component specifications and disassembly/assembly procedures). Detail Level: Detailed step-by-step instructions, torque specifications, tolerances, special tool requirements, and diagrams/illustrations. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable if properly created PDF. Print Quality Quality Expectation: High-resolution scans or original digital files, suitable for printing. Binding Type Binding: N/A (Digital Format) Paper Type Paper: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke, Liquid-Cooled, Single Cylinder Displacement: 193 cc (approximate, specific to 200 EXC) Bore X Stroke: Typical for this era's 200cc 2-strokes, specific dimensions would be in manual. Cooling System: Liquid Cooling (Radiator and Fan) Fuel Delivery: Carburetor (likely Keihin PWK 36 or similar) Ignition System: Digital CDI (Capacitor Discharge Ignition) Lubrication: Pre-mix fuel or Automatic Oil Injection (KTM's versions varied, check specific model year in manual) Performance Horsepower: Estimated 35-40 HP (at crankshaft, varies by year and specific tuning) Torque: Not typically published as prominently as HP for this class, but significant for its size. Fuel System Carburetor Model: Likely Keihin PWK 36mm or similar, exact model to be confirmed in manual. Fuel Type: Unleaded Gasoline (91-98 Octane recommended, check manual for specifics and pre-mix ratio if applicable) Engine Features Power Valve System: Likely features an electronically or mechanically controlled exhaust power valve for optimized torque and horsepower across the rev range. 🔧 Transmission Standard Type: 6-Speed Manual Transmission Clutch: Wet Multi-Plate Clutch (Likely...