🏷️ Basic Information Identification Make: KTM Model: 200 MXC Model Code: MXC 200 Generation Generation: First Generation (KTM EXC/MXC Series) Codes Production Years Covered: 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Vehicle Category: Off-road Competition/Enduro Motorcycle Target Audience: Motocross and Enduro riders, mechanics, enthusiasts Competitive Analysis Competitive Segment: Lightweight off-road competition bikes, often competing with models from Yamaha, Honda, Suzuki, and Husqvarna in the 125-250cc 2-stroke class. Key Features Vehicle Philosophy: Lightweight, agile, performance-oriented off-road machine with a potent 2-stroke engine. Manual Value Proposition: Essential resource for maintaining, troubleshooting, and repairing the KTM 200 MXC, crucial for preserving its performance and longevity. 📋 Manual Details Coverage Areas All Models Covered: Yes (All 200 MXC variants for the specified years) Page Count Estimated Page Count: 300-400 pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine System: Complete disassembly, assembly, inspection, and tuning of the 2-stroke engine. Fuel System: Carburetor tuning, jetting, float bowl adjustment, fuel line inspection, fuel filter replacement. Cooling System: Radiator maintenance, coolant replacement, fan operation (if applicable), hose inspection. Exhaust System: Expansion chamber inspection, muffler packing, sealing. Transmission System: Gearbox disassembly, inspection, lubrication, clutch operation, adjustment, and replacement. Drivetrain System: Chain and sprocket inspection, adjustment, and replacement, rear hub maintenance. Suspension System Front: Fork disassembly, seal replacement, oil type and level, spring inspection, valving. Brake System Front: Caliper overhaul, pad replacement, fluid bleeding, disc inspection, master cylinder service. Wheel And Tire: Spoke tensioning, rim inspection, bearing maintenance, tire pressure, mounting. Electrical System: Ignition system troubleshooting, lighting, wiring diagrams, battery maintenance. Chassis And Frame: Frame inspection for damage, steering head bearing service, subframe checks. Bodywork And Plastics: Fairing removal and installation, seat maintenance, graphics. Suspension System Rear Rear Suspension System: Monoshock absorber inspection, service, linkage maintenance, bearing checks. Brake System Rear Rear Brake System: Caliper overhaul, pad replacement, fluid bleeding, disc inspection, master cylinder service. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication, spark plug checks, air filter cleaning. Troubleshooting: Diagnostic guides for common starting, running, and performance issues. Engine Rebuild: Top-end and bottom-end rebuild procedures, piston ring installation, cylinder honing. Suspension Service: Complete fork and shock absorber service, including oil and seal changes. Brake System Repair: Bleeding, caliper rebuilding, master cylinder service. Clutch Adjustment And Replacement: Cable adjustment, clutch plate replacement. Electrical Diagnostics: Wiring diagram interpretation, component testing. Carburetor Rebuild And Jetting: Detailed steps for carburetor disassembly, cleaning, reassembly, and performance tuning. Technical Depth Depth Of Coverage: Comprehensive: Covers everything from basic adjustments to complete engine and chassis overhauls. Diagnostic Capability: Advanced: Includes troubleshooting charts and specific diagnostic procedures. Rebuild Instructions: Detailed step-by-step rebuild instructions with torque specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Print Quality Recommendation: High-resolution for clear diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type Recommendation: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke Single-Cylinder Displacement: 193 cc (approx.) Bore X Stroke: Typical: 62.5 mm x 65 mm (specific value to be confirmed in manual) Cooling System: Liquid-Cooled Power Valuation Metric: Horsepower (HP) Performance Estimated Horsepower: Around 35-40 HP (varies with tuning and specific year) Estimated Torque: Significant low-to-mid range torque characteristic of 2-strokes Fuel System Carburetor Type: Typically Keihin PWK (e.g., PWK 38) Fuel Type Recommendation: Unleaded gasoline, 95-98 RON, mixed with 2-stroke oil at specified ratio (e.g., 1:30 to 1:50). Reed Valve System: Yes, typically Moto Tassinari VForce or similar reed blocks. 🔧 Transmission Standard Transmission Type: 6-Speed Manual Features Clutch Type: Wet Multi-Plate Clutch 📐 Dimensions Exterior Wheelbase: Approx. 1460-1480 mm (146-148 cm) Weights Dry Weight: Around 100-105 kg (220-230 lbs) Fuel Tank Capacity: Approx. 10-12 Liters (2.6-3.2 Gallons) 🛡️ Safety Features Ratings Safety Ratings: N/A (Off-road competition vehicle, not subject to standard road safety ratings) Active Features Braking System: Hydraulic Disc Brakes (Front and Rear) Passive Features Frame Construction: High-strength Chromoly Steel Trellis Frame 💡 Technology Features Infotainment Infotainment System: N/A (Pure performance off-road machine, no infotainment features). Driver Assistance Driver Assistance Features: N/A (No electronic rider aids). Connectivity Connectivity Options: N/A 🔧 Maintenance Service Intervals Top End Rebuild Interval: Highly variable, but recommended around 40-80 hours of hard riding. Piston Ring Replacement: Typically 20-40 hours, depending on usage and engine condition. Spark Plug Check: Every 10-20 hours, or as per manual recommendation. Air Filter Cleaning: After every significant ride or as needed, depending on conditions. Chain Lubrication And Adjustment: Every riding session, and adjustment as needed for proper tension. Fluid Specifications Engine Oil Type: High-quality 2-stroke synthetic racing oil (specific brands and types to be detailed in manual). Transmission Oil Type: Gear oil, typically SAE 75W/80W or 80W/90W (specific API GL rating will be...