🏷️ Basic Information Identification Make: KTM Model: 200 EXC Model Code: 200 EXC Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Generation Generation Identifier: Early EXC 200 Models 👋 Introduction Market Position Segment: Performance Off-Road Motorcycle (Enduro/Cross Country) Target Audience: Enthusiast riders, amateur racers, and professional mechanics requiring detailed repair and maintenance information. Competitive Analysis Competitors Era: Suzuki RM250, Yamaha YZ250, Honda CR250 (2-stroke), Husqvarna WR250, GasGas EC250 of the same period. Key Features Brand Focus: KTM's reputation for high-performance, race-bred machinery. Model Advantage: The 200 EXC offered a potent blend of 125 agility and 250 power in a lightweight package, making it a niche but highly capable machine. Manual Value Proposition: Provides essential technical data for maintaining and repairing a performance off-road motorcycle, crucial for its longevity and optimal function. 📋 Manual Details Coverage Areas Coverage Scope: Complete Factory Service Repair Page Count Page Count Estimate: Hundreds of Pages (Specific count not provided, but indicative of comprehensive coverage) Manual Type Manual Type: Factory Service Repair Manual Language Language: English (Implied by product description and typical market) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine System: Detailed disassembly, assembly, inspection, and repair of all engine components including top-end (cylinder, piston, rings, head), bottom-end (crankshaft, connecting rod, bearings), cooling system, lubrication system, and power valve operation. Transmission And Drivetrain: Complete coverage of gearbox operation, clutch system (including wet multi-plate clutch), shift mechanism, chain and sprocket maintenance, and gearbox oil specifications. Fuel System: Carburetor (likely Keihin PWK based on era) overhaul, adjustment, jetting information, fuel lines, petcock, and tank maintenance. Electrical System: Wiring diagrams, ignition system (CDI, coil, spark plug), lighting, charging system (stator, regulator/rectifier), battery, and starter system (if applicable). Suspension System: Front fork (WP USD forks typical) disassembly, seal replacement, oil type and level specifications, damping adjustments, and rear shock absorber (WP PDS or similar) servicing and adjustments. Braking System: Front and rear hydraulic brake system maintenance, caliper overhaul, master cylinder service, brake fluid type and bleeding procedures, pad replacement, and rotor inspection. Cooling System: Radiator, hoses, water pump, and coolant specifications, bleeding procedures, and system pressure testing. Chassis And Frame: Frame inspection, steering head bearing service, swingarm and linkage maintenance, footpeg and lever adjustments, and general chassis component inspection. Bodywork And Plastics: Removal and installation of fenders, seat, fuel tank, side panels, and graphics. Procedures Included Maintenance Procedures: Regular service tasks, including oil changes, filter replacements (air and oil/screen), spark plug checks, chain adjustment, brake fluid changes, and tire pressure checks. Troubleshooting Guides: Systematic diagnostic procedures for common problems, including starting issues, engine performance problems, electrical faults, and suspension malfunctions. Engine Rebuild Procedures: Comprehensive instructions for top-end rebuilds, bottom-end overhauls, and complete engine disassembly and reassembly. Suspension Servicing: Detailed steps for fork seal replacement, damper rod service, and rear shock absorber rebuilds. Electrical Diagnostics: Fault finding based on symptoms, circuit testing, and component testing using multimeters. Brake System Maintenance: Bleeding procedures, caliper piston service, and master cylinder overhaul. Carburetor Tuning And Rebuild: Jetting recommendations, float height adjustment, and complete carburetor disassembly and cleaning. Technical Depth Diagnostic Capability: Advanced diagnostics for complex issues, including electrical system troubleshooting and performance tuning. Repair Scope: From basic routine maintenance to complete engine and gearbox rebuilds, including component-level repairs. Specifications Detail: Includes critical torque specifications, clearances, fluid levels, and diagnostic parameters for all major systems. Wiring Diagrams Completeness: Comprehensive and detailed wiring diagrams essential for electrical system diagnostics and repairs. 📊 Manual Specifications File Format File Format: PDF Searchability: Typically searchable text content for easy navigation (dependent on PDF creation). Print Quality Print Quality Recommendation: High resolution, suitable for printing all pages for workshop use. Binding Type Binding Type For Print: Digital Download (no physical binding) Paper Type Paper Type For Print: Standard paper (user choice for printing) ⚙️ Engine Specifications Primary Engine Engine Type: Two-Stroke Single Cylinder Displacement: 193 cc Bore X Stroke: 62.5 mm x 65 mm (Typical for this model) Cooling System: Liquid-Cooled Power Valve System: KTM's PowerJet or similar electronic/mechanical exhaust power valve system. Starting System: Kickstart Performance Horsepower Estimate: Approx. 35-40 HP (at crankshaft, subject to tuning and specific year) Torque Estimate: Approx. 25-28 Nm (at crankshaft, subject to tuning and specific year) Fuel System Carburetor Model: Keihin PWK 35 (Common fitment for this era) Fuel Type: Unleaded Premium Gasoline (95 Octane or higher recommended) Premix Ratio: 50:1 or 40:1 (using high-quality 2-stroke racing oil, as specified in manual) 🔧 Transmission Standard Transmission Type: 6-Speed Constant Mesh Clutch Type: Wet Multi-Plate Clutch Final Drive: Chain Drive Features Gearbox Oil Type: SAE 80W/90 Hypoid Gear Oil (KTM recommends specific grades, e.g., Motorex Gear Oil) Gearbox Oil Capacity: Approx. 0.7 Liters (0.74 US qt) (Verify in manual) 📐 Dimensions Exterior Wheelbase: Approx. 1455 mm (57.3 in) (Subject to year variation) Seat Height: Approx. 960 mm (37.8 in)...