🏷️ Basic Information Identification Make: KTM Model: 200 EXC Model Code: KTM 200 EXC Generation Model Years Covered: 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Segment: Off-road, Enduro Competitive Analysis Competitors 1999-2003: Husqvarna WR250, Yamaha YZ250 WR, Suzuki RMX250, Honda CR250R E Key Features Bike Focus: Lightweight, agile, powerful two-stroke performance for off-road competition and trail riding. 📋 Manual Details Coverage Areas Systems Covered: Engine, Transmission, Chassis, Electrical System, Suspension, Brakes, Fuel System, Cooling System, Exhaust System, Bodywork, Troubleshooting, Maintenance, Specifications Page Count Page Count: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures for the 200cc two-stroke engine. Transmission Service: Detailed instructions for gearbox maintenance, clutch service, and troubleshooting transmission issues. Chassis And Suspension: Procedures for fork and shock absorber service, linkage maintenance, frame inspection, and wheel bearing replacement. Electrical Diagnostics: Wiring diagrams, troubleshooting guides for ignition, lighting, and charging systems, as well as component testing. Brake System Maintenance: Guidance on brake pad replacement, caliper service, master cylinder maintenance, and bleeding procedures. Fuel And Carburetion: Detailed information on carburetor adjustment, cleaning, jetting, and fuel system component inspection. Frame And Bodywork: Repair procedures for plastic body panels, seat, fuel tank, and frame components. Procedures Included Routine Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, and spark plug service. Troubleshooting Guides: Systematic approaches to diagnosing and resolving common operational problems and failures. Major Repairs: Instructions for significant component overhauls and replacements, including engine rebuilds. Component Disassembly Reassembly: Step-by-step guides for taking apart and putting back together all major motorcycle systems. Engine Tuning: Basic tuning advice, carburetor jetting, and exhaust modification considerations. Wheel And Tire Service: Information on tire changes, wheel balancing, and spoke tensioning. Diagnostic Charts: Flowcharts and tables to systematically diagnose common problems. Technical Depth Depth Of Information: Comprehensive factory-level detail suitable for professional technicians and experienced DIY mechanics. Torque Specifications: Precise torque values for all critical fasteners. Clearances And Tolerances: Detailed specifications for engine component clearances, bearing tolerances, etc. Wiring Diagrams: Full electrical system schematics for troubleshooting and repairs. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution for clear reproduction of text and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Likely features searchable text within the PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, Single Cylinder Displacement: 192.7 cc (11.77 cu in) Bore X Stroke: 62.5 mm x 62.4 mm (2.46 in x 2.46 in) Cooling System: Liquid-cooled Carburetor: Keihin PWK 39 Performance Horsepower Approx: ~40 hp @ 8,500 rpm (Estimate, official figures vary) Torque Approx: ~35 Nm @ 7,500 rpm (Estimate, official figures vary) Fuel System Fuel Type: Unleaded gasoline with 2-stroke oil pre-mix Fuel Ratio: 1:40 or 1:50 (recommended by KTM) Ignition System Ignition Type: Digital CDI ignition system 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-disc clutch, hydraulically operated Features Gear Ratios: Specific ratios available in manual, typically focused on off-road performance. Transmission Oil Spec: KTM recommends specific gearbox oil, often a SAE 80W/90 API GL-4. 📐 Dimensions Exterior Wheelbase: Approx. 1470 mm (57.9 in) Ground Clearance: Approx. 350 mm (13.8 in) Weights Dry Weight: Approx. 104 kg (229 lbs) Fuel Tank Capacity: Approx. 9 liters (2.4 US gal) 🛡️ Safety Features Ratings Safety Certification: Not applicable for off-road competition motorcycles in the same way as street vehicles. Active Features Braking System: Hydraulic disc brakes front and rear. Brembo components often used. Passive Features Frame Construction: Chromoly steel trellis frame for rigidity and impact resistance. 💡 Technology Features Infotainment Infotainment Features: N/A (Basic off-road competition focus, no electronic infotainment systems). Driver Assistance Assistance Systems: N/A (Mechanical systems only). Connectivity Connectivity Options: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Refer to manual; typically every 15-25 hours of riding for gearbox oil. Top End Rebuild Interval: Highly variable based on use; can range from 50-100+ hours for piston/rings, and 100-200+ hours for a full engine rebuild. Fluid Specifications Engine Oil Type: Premix 2-stroke oil, specific grade and brand recommendations in manual. Coolant Type: Ethylene glycol-based antifreeze mixture. Brake Fluid Type: DOT 4 brake fluid. Fork Oil Type: Specific fork oil weight and level specified in the manual (e.g., WP suspension fluid). Known Issues Common Wear Items: Piston rings, clutch plates, wheel bearings, swingarm pivot bearings, steering head bearings, fork seals, exhaust packing. Potential Problems: Carburetor jetting sensitivity to altitude and temperature, reed valve wear, kickstart mechanism wear. 📚 Vehicle History Brand Heritage Ktm Offroad Legacy: KTM has a long-standing reputation for producing highly competitive off-road motorcycles, particularly in motocross and enduro racing. Model Evolution 200 Exc...