The 200 MXC is a high-performance, off-road competition motorcycle renowned for its potent 200cc, liquid-cooled, two-stroke engine and agile handling. Manufactured by the Austrian brand, celebrated for its off-road dominance, this model was designed for aggressive riding disciplines such as motocross and enduro. Its engineering emphasizes lightweight construction, featuring a chromoly steel trellis frame, and a powerful engine delivering strong low-to-mid range performance, making it a competitive choice in its class throughout its production years from the late 1990s to 2010. This comprehensive service repair manual covers the 200 MXC from 1999 to 2010, providing essential information for maintenance, repair, and troubleshooting. It details procedures for all major mechanical and electrical systems, including the engine, transmission, clutch, brakes, and suspension. The manual includes scheduled maintenance tasks, step-by-step repair instructions, diagnostic charts for common issues, and technical specifications. Its thorough coverage is intended to assist both novice owners and experienced technicians in keeping the vehicle in optimal condition and ensuring its longevity. 🏷️ Basic Information Identification Make: KTM Model: 200 MXC Engine Variant: 200cc Codes Model Code: 200 MXC (specific internal codes may vary by year and region) 👋 Introduction Market Position Segment: Off-road Enduro / Competition Motorcycle Competitive Analysis Competitors: Competed against models like Yamaha YZ250, Honda CR250R, Suzuki RM250 (in similar displacement classes for performance-oriented dirt bikes), though the 'MXC' designation points specifically to KTM's enduro line. Key Features Performance Focus: Lightweight, agile, potent 2-stroke engine, designed for aggressive off-road riding, motocross, and enduro disciplines. Engineering: Renowned KTM engineering for performance and durability in demanding off-road conditions. 📋 Manual Details Coverage Areas Applicable Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Pages: 300-500 (typical for comprehensive service manuals of this era, exact count not provided) Manual Type Type: Service Repair Manual Language Language: English (assumed, common for KTM service manuals) Format Format: PDF 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, tuning, troubleshooting, lubrication system, cooling system (if applicable), fuel system (carburetor, fuel pump), ignition system, exhaust system. Transmission: Gearbox internal components, clutch operation and adjustment, shift mechanism, lubrication. Chassis: Frame inspection and repair, suspension (forks, shock absorber), steering system, wheel bearings, brake system (hydraulic components, pad replacement, bleeding), electrical system (wiring diagrams, lighting, ignition components, charging system). Procedures Included Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, spark plug service, chain adjustment, brake pad inspection, general tune-ups. Repair: Detailed step-by-step repair procedures for all major mechanical and electrical components. Includes engine rebuild, gearbox overhaul, suspension repair, electrical fault diagnosis. Troubleshooting: Diagnostic charts and procedures for identifying and resolving common operational issues, performance problems, and component failures. Technical Depth Depth: Comprehensive, covering from basic routine maintenance to in-depth engine and component overhauls. Suitable for both DIY mechanics and professional technicians. 📊 Manual Specifications File Format File Type: PDF Searchability: Searchable text content (typical for high-quality PDF manuals) Print Quality Printability: Printable pages for workshop use Binding Type Binding: N/A (Digital PDF format) Paper Type Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Configuration: Single-cylinder, 2-stroke Displacement: 193cc (approximately) Bore X Stroke: 62.5 mm x 65 mm (typical for 200cc class) Cooling System: Liquid-cooled Ignition: Digital CDI Performance Horsepower: Approximately 35-40 HP (stock, depending on year and specific tuning) Torque: N/A (Specific torque figures not readily available, but known for strong low-to-mid range power) Fuel System Carburetor: Keihin PWK (e.g., 36mm, specific model may vary by year) Fuel Type: Unleaded gasoline with appropriate 2-stroke oil premix Lubrication Premix Ratio: Typically 40:1 or 50:1 (refer to manual for exact specification and recommended oil type) 🔧 Transmission Standard Type: 6-speed manual Clutch: Wet multi-plate clutch Features Gearbox Design: Robust KTM design for durability in off-road conditions. 📐 Dimensions Exterior Wheelbase: Approximately 1445-1470 mm (1470mm is common for this era KTM 200) Seat Height: Approximately 950-960 mm Weights Dry Weight: Approximately 95-105 kg Fuel Tank Capacity: Approximately 9-11 Liters 🛡️ Safety Features Ratings Crash Test Results: N/A (As it's a competition off-road motorcycle, official crash test ratings are not applicable). Active Features Brakes: Hydraulic disc brakes front and rear. Brembo calipers and rotors were standard on many KTM models of this era, known for excellent stopping power. Passive Features Frame Construction: Chromoly steel trellis frame, providing a balance of strength, rigidity, and light weight. 💡 Technology Features Infotainment Features: N/A (This is a pure competition off-road motorcycle; infotainment systems are not present.) Driver Assistance Features: N/A (No electronic rider aids such as ABS, traction control, etc.) Connectivity Features: N/A (No smart device integration or connectivity features.) 🔧 Maintenance Service Intervals Oil Change Engine: Every 10-15 hours of riding (typical for 2-stroke off-road bikes, check manual) Air Filter Cleaning: After every significant ride or as needed based on dust conditions. Spark Plug Service: Every 20-30 hours of riding, or as needed...