🏷️ Basic Information Identification Make: KTM Model: 200 EXC Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Model Code Range: Specific chassis codes may vary within these years; manual covers all 200 EXC variants. 👋 Introduction Market Position Vehicle Segment: Enduro Motorcycle Target Audience: Off-road enthusiasts, trail riders, and competitive enduro riders seeking performance and durability. Competitive Analysis Competitors: Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (two-stroke era). Key Features Engine Type: Aggressive two-stroke power delivery, lightweight design. Chassis: Strong chromoly steel frame, WP suspension components. Off Road Capability: Designed for demanding off-road conditions, including trails, hard enduro, and motocross. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Page Count: 280 Language: English Format: PDF Download Delivery Method: Instant Digital Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, and diagnostics for the 200cc two-stroke engine. Transmission: Clutch, gearbox (including gear inspection, replacement, and lubrication), and final drive maintenance. Fuel System: Carburetor (Mikuni VM28 or similar), fuel tank, fuel lines, and petcock maintenance and tuning. Ignition System: CDI ignition, spark plug specifications, timing adjustments, and troubleshooting. Cooling System: Liquid cooling system, radiator, hoses, water pump maintenance, and coolant specifications. Exhaust System: Expansion chamber, silencer inspection, and repacking procedures. Suspension: Front forks (WP USD), rear shock absorber (WP), suspension adjustments, oil changes, seal replacement, and general service. Brakes: Hydraulic disc brakes (front and rear), caliper service, pad replacement, fluid bleeding, master cylinder maintenance, and rotor specifications. Electrical System: Wiring diagrams, battery maintenance, lighting system, switchgear, and basic electrical troubleshooting. Frame And Bodywork: Frame inspection, handlebar and control adjustments, seat removal, body panel repair and fitting. Procedures Included Preventive Maintenance: Detailed schedules for oil changes, filter replacements, chain adjustment, and general inspections. Troubleshooting: Systematic guides for diagnosing common problems with the engine, transmission, electrical system, and chassis. Repair Procedures: Step-by-step instructions for component disassembly, repair, reassembly, and adjustment. Rebuilds: Comprehensive guides for engine and transmission rebuilds, including torque specifications and clearances. Technical Data Charts: Inclusion of specification tables, torque values, fluid capacities, and electrical resistance values. Technical Depth Depth: Advanced diagnostics and detailed repair procedures suitable for professional mechanics and experienced DIY enthusiasts. Diagnostic Tools: While specific diagnostic tool mentions might be limited, the manual provides the fundamental knowledge for diagnosing mechanical and electrical issues. 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable text within the PDF for quick information retrieval. Printable: High-quality PDF format suitable for printing individual sections or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, liquid-cooled, single-cylinder Displacement: Approximately 193 cc (bore x stroke typically around 62.5 mm x 64 mm) Bore X Stroke: Refer to manual for exact specifications, typically 62.5 x 64 mm Compression Ratio: Varies by year and specific tuning, typically around 8.5:1 to 9.5:1 for stock configuration. Performance Horsepower: Estimated 35-40 HP (stock configuration), power output can vary significantly with tuning and modifications. Torque: Refer to manual for exact specifications; known for strong low-to-mid range power. Fuel System Carburetor Type: Typically Mikuni VM28 or similar, with specific jetting and tuning recommendations in the manual. Fuel Type: Leaded or unleaded gasoline with appropriate octane rating, premixed with two-stroke oil. Oil Mixture Ratio: Refer to manual, typically 30:1 or 40:1, depending on oil type and riding conditions. Lubrication Engine Oil Type: Specific two-stroke engine oil required; refer to manual for recommended grades and specifications. 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Hydraulic actuated, multi-plate wet clutch. Features Gear Ratios: Specific gear ratios provided within the manual for detailed analysis and potential modification. Final Drive: Chain drive; manual includes chain inspection, adjustment, and sprocket replacement procedures. 📐 Dimensions Exterior Frame Type: Chromoly steel trellis frame Suspension Travel Front: Approximately 295-300 mm (WP USD forks) Suspension Travel Rear: Approximately 300-320 mm (WP Monoshock) Weights Dry Weight: Approximately 95-100 kg (varies slightly by year) Fuel Tank Capacity: Approximately 9-12 liters (varies by year and specific model variant) 🛡️ Safety Features Ratings Safety Features: N/A for off-road specific motorcycles in terms of formal crash ratings; focus is on rider control and vehicle stability. Active Features Brakes: Powerful hydraulic disc brakes front and rear for effective stopping power. Suspension: High-quality WP suspension provides optimal grip and control over varied terrain. Passive Features Frame Strength: Robust chromoly steel frame offers excellent rigidity and impact resistance. 💡 Technology Features Infotainment Infotainment System: N/A (Purely functional off-road motorcycle) Driver Assistance Electronic Aids: N/A (Mechanical focus, no electronic rider aids) Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual, typically every 15-20 hours of riding for 2-stroke premix. Air Filter Cleaning: Regularly, often every few rides or after dusty conditions; detailed cleaning and...