The 200 EXC, produced between 1999 and 2003, is a lightweight, agile, and potent 2-stroke, liquid-cooled enduro motorcycle renowned for its performance in off-road competitions and trail riding. This model, often equipped with high-quality WP Suspension components, exemplifies dedication to a 'Ready to Race' philosophy, offering a strong power-to-weight ratio that appeals to enthusiast riders. Its robust chromium-molybdenum steel perimeter frame and advanced suspension travel are engineered to handle demanding terrain, making it a competitive choice in its segment. This workshop repair service manual provides comprehensive guidance for the maintenance and repair of your 200 EXC from the 1999-2003 model years. It covers all essential systems, including detailed procedures for engine mechanicals, fuel and ignition systems, transmission, brakes, suspension, and electrical systems. The manual is designed for both professional technicians and experienced DIY enthusiasts, offering step-by-step instructions for disassembly, assembly, adjustments, and troubleshooting, ensuring optimal performance and longevity of your motorcycle. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC Generation: First Generation (based on model years) Product Name: KTM 200 EXC 1999-2003 Workshop Repair Service Manual PDF Download 👋 Introduction Market Position Segment: Enduro / Off-Road Competition Motorcycle Target User: Enthusiast riders participating in enduro events, trail riding, and off-road competitions. Competitive Analysis Competitors Circa 1999-2003: Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (2-stroke counterparts); potentially GasGas EC250, Husqvarna WR250. Key Features Engine Type: 2-stroke, liquid-cooled, single-cylinder (distinct from larger 4-stroke models). Performance Focus: Lightweight, agile, potent power delivery for off-road use. Suspension Brand: Often equipped with WP Suspension components, a hallmark of KTM's performance. 📋 Manual Details Coverage Areas Supported Model Years: 1999, 2000, 2001, 2002, 2003 Supported Variants: All Models (assumed to cover all 200 EXC configurations within these years) Page Count Estimated Page Count: Detailed page count not specified, but typical for a comprehensive workshop manual of this era would be 300-600 pages. Manual Type Type: Workshop Repair Service Manual Language Language: Likely English, but confirmation with seller advised for specific edition. Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine assembly, disassembly, overhaul, top-end (cylinder, piston, rings, head), bottom-end (crankshaft, connecting rod, bearings), valve train, lubrication system, cooling system. Fuel System: Carburetor specifications, adjustment, cleaning, and overhaul. Fuel tank, fuel lines, fuel petcock operation and maintenance. Ignition System: CDI unit, spark plug specifications, ignition timing, troubleshooting of ignition faults. Transmission Drivetrain: Gearbox assembly and disassembly, clutch operation and adjustment, chain and sprockets maintenance, lubrication. Suspension: Front fork (WP Suspension likely) disassembly, service, seal replacement, oil level and type. Rear shock absorber service, adjustments, and rebuild procedures. Brakes: Front and rear brake caliper service, pad replacement, fluid bleeding, master cylinder overhaul. Brake disc specifications. Electrical System: Wiring diagrams, lighting system, battery maintenance, charging system (stator, regulator/rectifier), starter system (if applicable, though typically kick-start for this model), fuses, switches, and control units. Frame Chassis: Frame inspection, headstock bearings, swingarm service, wheel bearings, spokes and rims maintenance, chain adjustment. Bodywork Plastics: Removal and installation of body panels, seat, fuel tank, fenders. Troubleshooting: Diagnostic procedures for common problems, fault finding charts for engine, electrical, and mechanical issues. Procedures Included Preventative Maintenance: Scheduled maintenance tasks, lubrication points, cleaning procedures, periodic checks. Disassembly Assembly: Step-by-step instructions for complete component disassembly and reassembly. Repair Rebuild: Detailed procedures for repairing and rebuilding major components like the engine, transmission, and suspension. Adjustments: Carburetor settings, clutch lever free play, chain tension, suspension preload, and damping adjustments. Diagnostic Tests: Methods for diagnosing electrical faults, engine performance issues, and mechanical problems. Technical Depth Depth: Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced troubleshooting. Target Audience: Professional motorcycle technicians and experienced DIY enthusiasts. Specificity: Highly specific technical data, torque specifications, clearance measurements, and detailed schematics. 📊 Manual Specifications File Format File Type: PDF Searchability: Typically searchable text within PDF, allowing for quick information retrieval. Printable: Yes, designed for printing specific sections or the entire manual. Print Quality Quality: Depends on the original source scanned. High-quality PDF scans are expected for professional manuals. Binding Type Binding: N/A (PDF format, but original manual would be saddle-stitched or perfect bound). Paper Type Paper: N/A (PDF format, but original manual typically on durable paper stock). ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, 2-stroke Displacement: 193cc (95 x 65.5 mm bore x stroke) Cooling System: Liquid-cooled Induction: Reed valve induction, carburetor fed. Ignition: CDI (Capacitor Discharge Ignition) Power Output: Estimated 35-40 HP (subject to specific model year tuning and regional variations). Torque Output: Not explicitly stated, but characterized by strong mid-range torque. Fuel System Carburetor Model: Likely Keihin PWK (e.g., PWK 35) or similar performance carburetor. Fuel Type: Unleaded gasoline (minimum 95 octane recommended) mixed with 2-stroke oil. Fuel Mix Ratio: Typically 1:40 or 1:50 (oil to gasoline), consult manual for specific ratio and oil type. Lubrication 2 Stroke Oil Type: High-quality 2-stroke...