This workshop service manual covers 200 EXC, XC, and XC-W models produced between 1999 and 2010. These motorcycles are engineered for high-performance off-road riding, offering a lightweight and agile platform with a potent 2-stroke engine. Known for their racing heritage and robust build, models in this segment are designed for aggressive trail riding and competition. The 200cc class provides a unique balance of power and manageability, making these bikes a favorite among riders seeking thrilling off-road experiences. This comprehensive manual serves as an essential resource for the maintenance, repair, and troubleshooting of your 200 EXC, XC, or XC-W. It details all major systems, including the engine, fuel, ignition, cooling, exhaust, transmission, chassis, suspension, and brakes. With step-by-step procedures, technical specifications, and diagnostic guidance, this manual empowers owners and technicians to ensure optimal performance and longevity of the vehicle. Coverage includes routine maintenance, detailed engine and transmission overhauls, suspension servicing, brake system repairs, and electrical diagnostics. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC, XC, XC-W Product Type: Workshop Service Manual Product Format: PDF Download 👋 Introduction Market Position Segment: High-performance off-road motorcycle segment (Enduro/Cross-Country). Competitive Analysis Competitors: Competes with models from Yamaha (YZ250, WR250), Honda (CRF250X, CR250R), Suzuki (RM-Z250, DR-Z250), Kawasaki (KX250, KLX250). Key Features Vehicle Focus: Lightweight, agile, and powerful 2-stroke performance for off-road competition and aggressive trail riding. Manual Value Proposition: Essential for owners and technicians to maintain, repair, and optimize the performance of these specialized off-road machines. 📋 Manual Details Coverage Areas Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Pages: 280 Manual Type Type: Workshop Service Manual Language Language: English Format Format: Digital PDF 📖 Manual Coverage Systems Covered Engine: Comprehensive engine disassembly, assembly, inspection, and repair for the 200cc 2-stroke engine. Fuel System: Carburetor (Keihin PWK likely) tuning, cleaning, rebuilding, and fuel delivery system diagnostics. Ignition System: CDI ignition system, spark plug specifications, coil testing, and troubleshooting. Cooling System: Liquid cooling system, radiator, water pump, thermostat, and coolant specifications and flushing procedures. Exhaust System: Exhaust pipe, silencer, and power valve system inspection and maintenance. Transmission: 6-speed gearbox overhaul, clutch (hydraulic actuation likely) inspection and replacement, gear shift mechanism. Chassis: Frame inspection, handling, and general chassis component integrity. Suspension Front: WP Suspension forks (likely USD type), internal component inspection, oil changes, seal replacement, and adjustment procedures. Suspension Rear: WP Monoshock absorber, linkage system maintenance, bearing checks, and shock absorber servicing. Brakes Front: Hydraulic disc brake system, caliper overhaul, pad replacement, fluid flush and bleeding, master cylinder servicing. Brakes Rear: Hydraulic disc brake system, caliper overhaul, pad replacement, fluid flush and bleeding, master cylinder servicing. Wheels Tires: Spoke tensioning, wheel bearing replacement, tire mounting and balancing, recommended tire pressures. Electrical System: Wiring diagrams, lighting system, battery maintenance, fuse checks, and starter system (kick-start primary). Bodywork Fairings: Fairing removal and installation, seat, fuel tank, and fender components. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning, spark plug checks. Engine Rebuild: Top-end rebuild (piston, rings, cylinder, cylinder head), bottom-end rebuild (crankshaft, bearings, seals), power valve service. Transmission Overhaul: Complete gearbox disassembly, inspection of gears, shafts, and shift drum, clutch assembly and disassembly. Suspension Servicing: Fork oil replacement, seal head replacement, shock absorber service, linkage bearing lubrication. Brake System Repair: Brake caliper piston replacement, seal kits, brake line replacement, bleeding procedures. Troubleshooting: Diagnostic steps for common running issues, electrical faults, and mechanical problems. Carburetor Adjustment: Idle speed, jetting, mixture screw, and float height adjustments. Electrical Diagnostics: Using wiring diagrams to trace faults, testing components like stator, CDI, and regulator/rectifier (if applicable). Technical Depth Depth: Comprehensive, covering from basic maintenance to complete engine and transmission rebuilds. Detail Level: Detailed step-by-step instructions with torque specifications, clearances, and diagnostic procedures. Visuals: Likely includes diagrams, illustrations, and exploded views for clarity. 📊 Manual Specifications File Format Format: PDF Searchable: Yes (typically, depends on PDF creation) Printable: Yes Print Quality Quality: Digital - Quality dependent on source scan/creation, generally high for professional manuals. Binding Type Binding: Not applicable (Digital Download) Paper Type Paper: Not applicable (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 2-stroke, single-cylinder, liquid-cooled Displacement: 193 cc (approx.) Bore X Stroke: Typically around 62.5 mm x 65 mm (exact spec to be confirmed in manual). Power Valve: KTM's patented exhaust power valve system for optimized torque and horsepower across the rev range. Performance Horsepower: Estimated 35-40 HP (peak, varies by model year and tuning). Torque: Estimated 20-24 lb-ft (peak, varies by model year and tuning). Fuel System Carburetor: Keihin PWK 38mm (common for this era and model, specific jetting in manual). Fuel Type: Unleaded gasoline, minimum 91 octane (RON + MON)/2. Lubrication Premix: Required 2-stroke oil premixed with gasoline (ratio specified in manual, typically 50:1 or 60:1). Starting System System: Kickstarter 🔧 Transmission Standard Type: 6-speed, constant...