This manual covers the 200 XC-W, a high-performance, lightweight off-road motorcycle renowned for its agile handling and potent two-stroke performance. Produced from 1999 through 2010, this model embodies the 'Ready to Race' philosophy, making it a favored choice for enthusiast riders and racers engaged in aggressive trail riding and competition. The 200 XC-W is characterized by its robust engineering, designed to deliver exceptional performance in demanding off-road environments, building on an extensive legacy in motorsports. This comprehensive workshop and service repair manual provides detailed information essential for the maintenance and repair of your 200 XC-W. It covers a wide array of critical systems, including engine mechanical and electrical components, fuel system, transmission, suspension, brakes, and general chassis and electrical systems. The manual includes step-by-step procedures for routine maintenance, major repairs, component rebuilding, and diagnostic troubleshooting, along with essential technical specifications and wiring diagrams, ensuring owners and technicians can effectively maintain and restore the vehicle's optimal performance and reliability. 🏷️ Basic Information Identification Make: KTM Model: 200 XC-W Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Product Type: Service Repair Workshop Manual Format: PDF Download 👋 Introduction Market Position Vehicle Segment: High-performance off-road motorcycle, specifically a lightweight enduro/cross-country model. Competitive Analysis Key Competitors Era: Competed against models from brands like Yamaha (YZ series), Honda (CRF series), Suzuki (RM series), Kawasaki (KX series), Husqvarna, and Sherco in the lightweight off-road segment. Key Features Design Philosophy: Known for KTM's 'Ready to Race' philosophy, emphasizing lightweight construction, agile handling, and potent two-stroke performance. Target Audience Intended User: Enthusiast riders and racers seeking a nimble and powerful off-road machine for competition and aggressive trail riding. 📋 Manual Details Coverage Areas Comprehensive Coverage: Full service, repair, and diagnostic information for the specified KTM 200 XC-W models. Page Count Estimated Pages: 300-400 (typical for comprehensive workshop manuals of this era, specific count not provided in product data) Manual Type Type: Workshop Manual / Service Manual / Repair Manual Language Language: English (presumed, standard for major market manuals) Format Digital Format: Searchable PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, inspection, assembly, timing, valve adjustment, piston and cylinder work, crankshaft and connecting rod service. Engine Electrical: Ignition system, stator, CDI unit, spark plug diagnosis, wiring diagrams, charging system. Fuel System: Carburetor tuning and rebuilding (likely Keihin or Mikuni), fuel tank, fuel lines, petcock operation. Transmission Drivetrain: Clutch operation and adjustment, gearbox disassembly and reassembly, chain and sprockets. Suspension: Front fork (WP Suspension) disassembly, servicing, oil changes, seal replacement, rear shock absorber servicing, linkage maintenance. Brakes: Front and rear brake system servicing, caliper overhaul, master cylinder maintenance, bleeding procedures, pad replacement. Cooling System: Radiator, coolant hoses, water pump, coolant replacement and bleeding (if applicable). Exhaust System: Exhaust pipe and silencer inspection and maintenance. Wheels Tires: Wheel bearing service, spoke tensioning, tire changes. Chassis Frame: Frame inspection, steering head bearing service. Electrical System General: Lighting, horn, battery maintenance, wiring harness inspection. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, tire pressure checks. Diagnostic Troubleshooting: Step-by-step troubleshooting guides for common performance issues, starting problems, electrical faults. Major Repairs: Engine rebuilds, transmission overhauls, suspension component replacement, brake system repairs. Component Rebuilding: Detailed instructions for rebuilding carburetors, water pumps, brake calipers, and other key components. Technical Specifications Data: Torque values for critical fasteners, engine clearances, fluid capacities, electrical specifications. Wiring Diagrams: Comprehensive electrical wiring diagrams for easy fault finding and system understanding. Technical Depth Depth Level: Comprehensive and detailed, suitable for both experienced mechanics and diligent DIY owners. Diagnostic Capabilities: Advanced diagnostic procedures focusing on identifying root causes of malfunctions. Rebuild Instructions: Detailed, step-by-step instructions for complete engine and major component rebuilds. 📊 Manual Specifications File Format File Type: PDF Print Quality Image Resolution: High-resolution (assumed for clear diagrams and text) Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) Searchability Text Search: Searchable text for quick information retrieval. Printability Printable Pages: Printable pages for offline use or referencing during repairs. ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled Displacement: 193 cc (approximate, exact for specific model years may vary slightly) Bore X Stroke: 62.5 mm x 64 mm (typical for this displacement) Carburetion: Keihin PWK 36 (common for this generation XC-W) Performance Horsepower: Approx. 35-40 HP (estimated, varies by year and specific tuning) Torque: Approx. 24-27 Nm (estimated) Fuel System Fuel Type: Unleaded gasoline with 2-stroke oil pre-mix (ratio specified in manual) Fuel Delivery: Carburetor 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch: Wet multi-disc clutch, hydraulically operated Features Gear Ratios: Specific gear ratios will be detailed within the manual. Final Drive: Chain drive 📐 Dimensions Exterior Wheelbase: Approximately 1450-1480 mm (varies by year) Weights Dry Weight: Approximately 98-102 kg (varies by year and equipment) Fuel Tank Capacity:...