This manual covers the 200 XC, a performance-oriented off-road motorcycle produced from 1999 through 2010. Renowned for its lightweight agility and potent 2-stroke engine performance, the 200 XC is engineered for competitive off-road riding and aggressive trail use. A heritage in off-road racing underpins the development of this model, emphasizing a strong power-to-weight ratio and robust construction, characteristic of a dedication to off-road excellence. This comprehensive workshop service and repair manual provides essential information for technicians, DIY mechanics, and enthusiasts. It details maintenance procedures, troubleshooting guidance, technical specifications, and disassembly/reassembly instructions for all major systems, including the engine, transmission, chassis, brakes, and electrical components. With 280 pages of detailed content, this manual empowers users to maintain peak performance, diagnose issues efficiently, and conduct all necessary repairs, ensuring the longevity and optimal operation of the 200 XC. 🏷️ Basic Information Identification Make: KTM Model: 200 XC Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Engine Variant Covered: 200cc (specific variant details to be confirmed via manual content) 👋 Introduction Market Position Segment: Off-Road Competition (XC - Cross Country) Category: Performance Off-Road Motorcycle Competitive Analysis Competitors: Husqvarna WR250, Gas Gas EC250, Beta RR250, Yamaha YZ250 (depending on specific year comparisons, though 200cc is a niche) Key Features Vehicle Focus: Lightweight, agile, potent 2-stroke performance for off-road racing and aggressive trail riding. Manual Benefit: Enables owners and technicians to maintain peak performance, diagnose issues efficiently, and perform all necessary repairs. 📋 Manual Details Coverage Areas Primary Coverage: Workshop Service and Repair Target Audience: KTM Technicians, DIY Mechanics, Enthusiasts Page Count Total Pages: 280 Manual Type Type: Workshop Service Manual Language Language: English (presumed, standard for KTM technical documentation) Format Format: PDF (Digital Download) 📖 Manual Coverage Systems Covered Engine: Complete overhaul, tuning, carburetor adjustment, ignition system, cooling system (if applicable), lubrication system. Transmission: Clutch operation, gearbox disassembly and reassembly, shift mechanism, lubrication. Chassis: Frame inspection and repair, suspension (forks, rear shock), steering system, wheels and hubs. Brakes: Hydraulic brake system (front and rear calipers, master cylinders, lines), pad replacement, fluid bleeding, rotor inspection. Electrical: Wiring diagrams, lighting system, ignition system components, battery maintenance, charging system (stator, rectifier). Bodywork: Fairing removal and installation, seat, fuel tank, fenders. Controls: Throttle assembly, clutch lever, brake lever, footpegs, handlebars. Procedures Included Maintenance: Regular service intervals, lubrication points, filter changes, spark plug replacement, chain adjustment. Repair: Step-by-step instructions for all major component repairs and replacements. Troubleshooting: Diagnostic flowcharts and common problem identification for various systems. Disassembly Reassembly: Detailed procedures for component removal and reinstallation. Technical Depth Depth: Comprehensive: Covers routine maintenance, advanced diagnostics, and complete engine/component rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable PDF (likely, typical for professional manuals) Print Quality Quality: High-resolution (expected for professional workshop manuals, suitable for printing) Binding Type Type: N/A (Digital Download) Paper Type Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 2-Stroke, Single Cylinder Displacement: 193cc (approximate for KTM 200 models of this era) Bore X Stroke: 62.5 mm x 64 mm (typical for KTM 200s) Cooling System: Liquid-Cooled Performance Horsepower: Approximately 35-40 HP (estimate based on era and displacement) Torque: Not readily available for specific model year, but expected to provide strong mid-range power. Fuel System Carburetor: Keihin PWK 36 (typical for KTM 200 XC of this period) Fuel Type: Unleaded Gasoline (91 octane or higher recommended) Oil Mixture: Pre-mix (typically 50:1 or 40:1 with high-quality 2-stroke oil, refer to manual for exact specification) 🔧 Transmission Standard Type: 6-Speed Manual Clutch: Wet Multi-Plate Clutch Features Gear Ratios: Specific gear ratios are detailed within the workshop manual. Final Drive: Chain Drive 📐 Dimensions Exterior Wheelbase: Approximately 1460 mm (57.5 inches) - subject to variation by year. Weights Dry Weight: Approximately 100-105 kg (220-231 lbs) - subject to variation by year. Fuel Capacity: Approximately 8-10 Liters (2.1-2.6 US Gallons) - subject to variation by year. 🛡️ Safety Features Ratings Crash Test Ratings: N/A (Motorcycles typically do not undergo standardized crash testing like passenger cars). Active Features Braking: Hydraulic Disc Brakes (Front and Rear) Passive Features Frame Construction: Chromoly Steel Trellis Frame (characteristic of KTM off-road bikes) 💡 Technology Features Infotainment Features: N/A (Basic off-road motorcycle, focus is on performance and durability, not electronics beyond essential functions). Driver Assistance Features: N/A Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change: Refer to manual for specific interval based on riding conditions; typically every 10-15 hours of hard use or annually. Air Filter Cleaning: Frequent cleaning recommended for off-road use; every 5-10 hours or as needed. Spark Plug Replacement: Refer to manual; typically every 20-40 hours of operation. Fluid Specifications Engine Oil Transmission Oil: KTM specifies specific gearbox oil (e.g., Motorex Gear Oil 80W) and 2-stroke premix oil. Manual will list exact specifications. Coolant: Ethylene Glycol Based Coolant (50/50 mix with distilled water)...