The 200 EXC, produced from 1999 through 2010, is a celebrated enduro motorcycle renowned for its aggressive two-stroke power delivery and lightweight, agile design. Built upon a robust chromoly steel frame and equipped with high-performance suspension components, this model is engineered for demanding off-road conditions, excelling in trails, hard enduro, and motocross riding. The strong off-road racing heritage is evident in the 200 EXC's platform, which consistently refined its engine performance, suspension tuning, and component durability throughout its production years, making it a favored choice among off-road enthusiasts and competitive riders. This comprehensive workshop service and repair manual, presented in English, covers the 200 EXC models from 1999 to 2010. Within its 280 pages, you will find detailed instructions for engine overhaul, transmission maintenance, fuel and ignition system tuning, cooling system service, suspension adjustments, brake system repair, and electrical system troubleshooting. The manual also includes essential preventive maintenance schedules, systematic diagnostic guides for common issues, and in-depth procedures for component rebuilds, all supported by technical data charts and specifications. This resource is designed to assist owners, mechanics, and technicians in effectively maintaining and repairing the vehicle to ensure optimal performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Model Code Range: Specific chassis codes may vary within these years; manual covers all 200 EXC variants. 👋 Introduction Market Position Vehicle Segment: Enduro Motorcycle Target Audience: Off-road enthusiasts, trail riders, and competitive enduro riders seeking performance and durability. Competitive Analysis Competitors: Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (two-stroke era). Key Features Engine Type: Aggressive two-stroke power delivery, lightweight design. Chassis: Strong chromoly steel frame, WP suspension components. Off Road Capability: Designed for demanding off-road conditions, including trails, hard enduro, and motocross. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Page Count: 280 Language: English Format: PDF Download Delivery Method: Instant Digital Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, disassembly, assembly, tuning, and diagnostics for the 200cc two-stroke engine. Transmission: Clutch, gearbox (including gear inspection, replacement, and lubrication), and final drive maintenance. Fuel System: Carburetor (Mikuni VM28 or similar), fuel tank, fuel lines, and petcock maintenance and tuning. Ignition System: CDI ignition, spark plug specifications, timing adjustments, and troubleshooting. Cooling System: Liquid cooling system, radiator, hoses, water pump maintenance, and coolant specifications. Exhaust System: Expansion chamber, silencer inspection, and repacking procedures. Suspension: Front forks (WP USD), rear shock absorber (WP), suspension adjustments, oil changes, seal replacement, and general service. Brakes: Hydraulic disc brakes (front and rear), caliper service, pad replacement, fluid bleeding, master cylinder maintenance, and rotor specifications. Electrical System: Wiring diagrams, battery maintenance, lighting system, switchgear, and basic electrical troubleshooting. Frame And Bodywork: Frame inspection, handlebar and control adjustments, seat removal, body panel repair and fitting. Procedures Included Preventive Maintenance: Detailed schedules for oil changes, filter replacements, chain adjustment, and general inspections. Troubleshooting: Systematic guides for diagnosing common problems with the engine, transmission, electrical system, and chassis. Repair Procedures: Step-by-step instructions for component disassembly, repair, reassembly, and adjustment. Rebuilds: Comprehensive guides for engine and transmission rebuilds, including torque specifications and clearances. Technical Data Charts: Inclusion of specification tables, torque values, fluid capacities, and electrical resistance values. Technical Depth Depth: Advanced diagnostics and detailed repair procedures suitable for professional mechanics and experienced DIY enthusiasts. Diagnostic Tools: While specific diagnostic tool mentions might be limited, the manual provides the fundamental knowledge for diagnosing mechanical and electrical issues. 📊 Manual Specifications File Format Format: PDF Searchable: Likely searchable text within the PDF for quick information retrieval. Printable: High-quality PDF format suitable for printing individual sections or the entire manual. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, liquid-cooled, single-cylinder Displacement: Approximately 193 cc (bore x stroke typically around 62.5 mm x 64 mm) Bore X Stroke: Refer to manual for exact specifications, typically 62.5 x 64 mm Compression Ratio: Varies by year and specific tuning, typically around 8.5:1 to 9.5:1 for stock configuration. Performance Horsepower: Estimated 35-40 HP (stock configuration), power output can vary significantly with tuning and modifications. Torque: Refer to manual for exact specifications; known for strong low-to-mid range power. Fuel System Carburetor Type: Typically Mikuni VM28 or similar, with specific jetting and tuning recommendations in the manual. Fuel Type: Leaded or unleaded gasoline with appropriate octane rating, premixed with two-stroke oil. Oil Mixture Ratio: Refer to manual, typically 30:1 or 40:1, depending on oil type and riding conditions. Lubrication Engine Oil Type: Specific two-stroke engine oil required; refer to manual for recommended grades and specifications. 🔧 Transmission Standard Type: 6-speed constant mesh Clutch: Hydraulic actuated, multi-plate wet clutch. Features Gear Ratios: Specific gear ratios provided within the manual for...