🏷️ Basic Information Identification Make: KTM Model: 200 EXC Model Variant: Enduro / Off-Road Competition Product Type: Factory Service Repair Manual Codes Platform Code: Likely related to KTM's EXC platform evolution during this period, specific internal codename not provided but indicative of a consistent chassis/engine family. Engine Code Identifier: Typically designated by cubic capacity and minor variations, e.g., 200cc two-stroke. 👋 Introduction Market Position Segment: Lightweight Enduro / Off-Road Competition Motorcycle Target Audience: Enthusiasts, racers, and mechanics involved in competitive off-road riding and maintenance of the KTM 200 EXC. Competitive Analysis Key Competitors: Honda CR250R/CRF250X, Yamaha YZ250/WR250F, Suzuki RM250/RMX250, Kawasaki KX250/KDX250. Key Features Vehicle Focus: Agility, lightweight performance, strong power-to-weight ratio, competitive off-road capability. Manual Value Proposition: Provides essential factory-backed information for maintaining and repairing the 200 EXC, crucial for optimizing performance and longevity in demanding off-road conditions. 📋 Manual Details Coverage Areas Covered Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Primary Market Focus: Global Language: English (assumed, standard for factory manuals unless otherwise specified) Page Count Estimated Pages: Variable, typically 300-600 pages for this era of comprehensive service manuals. Manual Type Type: Factory Service Repair Manual (FSM) Format Digital Format: PDF Download 📖 Manual Coverage Systems Covered Powertrain: Engine (disassembly, assembly, tuning, lubrication, cooling, exhaust), Transmission (clutch, gearbox, shifting mechanism), Fuel System (carburetor, fuel lines, petcock), Ignition System (CDI, spark plug, wiring). Chassis: Frame, Swingarm, Suspension (front forks, rear shock absorber, linkages), Steering system, Wheel bearings, Triple clamps. Brakes: Hydraulic brake system (master cylinders, calipers, brake lines, levers, pedals), Rotor specifications, Pad wear limits. Electrical: Lighting system (headlight, taillight, indicators), Wiring diagrams, Battery system, Charging system (stator, regulator/rectifier), Fuses, Switches, Instrument cluster. Bodywork And Controls: Plastics (fenders, shrouds, seat), Handlebars, Levers, Footpegs, Cables (throttle, clutch), Seat removal and installation. Procedures Included Maintenance: Routine service intervals, oil changes, filter replacements (air, fuel, oil), chain adjustment, spark plug checks, valve clearance checks (if applicable, though this is a 2-stroke). Diagnostics And Troubleshooting: Systematic fault finding for common issues, electrical troubleshooting charts, engine performance diagnosis. Repair And Rebuild: Complete engine disassembly and reassembly procedures, transmission rebuilds, suspension fork servicing, brake caliper overhauls, carburetor rebuilds. Adjustments: Carburetor jetting and adjustment, clutch cable adjustment, brake lever free play adjustment, suspension sag adjustment. Technical Depth Depth: Comprehensive; covers from basic owner maintenance to complete engine and chassis rebuilds, including detailed torque specifications, clearances, and diagnostic procedures. Diagnostic Tools And Techniques: Includes information on identifying worn components, diagnosing performance issues, and using specialized tools where applicable. 📊 Manual Specifications File Format Format: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Quality: High resolution, designed for clear viewing and printing of diagrams and text. Binding Type Digital Binding: N/A (Digital download) Paper Type Digital Paper Type: N/A (Digital download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, Single-cylinder Displacement: 193 cc (approximately) Bore X Stroke: Typically around 62.5 mm x 65 mm (exact figures in manual). Cooling System: Liquid-cooled Performance Horsepower: Estimated 30-40 HP (specific figures in manual). Torque: Estimated 20-25 lb-ft (specific figures in manual). Fuel System Carburetor Type: Keihin PWK (e.g., 36mm, precise model and jetting in manual). Fuel Type: Unleaded gasoline, often recommended with a specific octane rating and pre-mix ratio for 2-stroke oil. Ignition Ignition System: Digital CDI Lubrication 2-Stroke Oil Injection: Automatic oil injection system (specific oil type and recommendations in manual). 🔧 Transmission Standard Type: 6-speed constant mesh Clutch Type: Wet multi-plate, hydraulic actuation Optional Type: N/A (Standard configuration for EXC models) Features Gear Ratios: Specific gear ratios for each of the 6 speeds will be detailed in the manual. Transmission Oil: Separate transmission oil (specific type and capacity in manual, often SAE 10W/15W-40). 📐 Dimensions Exterior Wheelbase: Approximately 1460-1480 mm (specific to year and variant, detailed in manual). Seat Height: Approximately 920-940 mm (unladen, specific to year and variant, detailed in manual). Ground Clearance: Approximately 350-370 mm (unladen, specific to year and variant, detailed in manual). Weights Dry Weight: Approximately 95-105 kg (specific to year and variant, detailed in manual). Fuel Tank Capacity: Typically 8-12 liters (specific to year and variant, detailed in manual). 🛡️ Safety Features Ratings Crash Test Results: N/A (Off-road competition motorcycles are not typically subject to standardized crash testing like street vehicles). Active Features Braking System: Hydraulic disc brakes front and rear (performance specifications and fluid types in manual). Suspension Performance: High-performance adjustable suspension (detailed setup and service in manual). Passive Features Frame Construction: Chromoly steel trellis frame (strength and integrity details in manual). Ergonomics: Designed for rider control and maneuverability in off-road conditions. 💡 Technology Features Infotainment Features: Basic instrumentation; typically includes a speedometer, odometer, trip meter, and indicator lights. No advanced infotainment systems on this model. Driver Assistance Features: N/A (Off-road competition focus, no electronic rider aids). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil...