The KTM 200 EXC, produced between 1999 and 2003, is a highly capable off-road motorcycle renowned for its lightweight design, agile handling, and potent two-stroke performance. Engineered for demanding enduro and trail riding conditions, this model embodies KTM's strong heritage in off-road competition. Its robust 192.7 cc liquid-cooled engine, paired with a 6-speed transmission and hydraulically operated clutch, delivers exhilarating power and precise control. The advanced chassis, featuring a chromoly steel trellis frame and high-quality suspension components, ensures durability and responsiveness on challenging terrain, making it a favored choice for riders seeking a competitive edge. This comprehensive Factory Service Repair Manual provides in-depth information for the maintenance, repair, and servicing of the KTM 200 EXC models from 1999 to 2003. It covers all essential systems, including the engine, transmission, chassis, electrical system, suspension, brakes, and fuel system. The manual offers detailed procedures for routine maintenance, major repairs, engine overhauls, and component disassembly and reassembly, along with systematic troubleshooting guides and diagnostic charts. With factory-level detail and precise torque specifications, this English-language manual is an indispensable resource for owners, mechanics, and technicians aiming to keep their 200 EXC performing at its peak. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC Model Code: KTM 200 EXC Generation Model Years Covered: 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Segment: Off-road, Enduro Competitive Analysis Competitors 1999-2003: Husqvarna WR250, Yamaha YZ250 WR, Suzuki RMX250, Honda CR250R E Key Features Bike Focus: Lightweight, agile, powerful two-stroke performance for off-road competition and trail riding. 📋 Manual Details Coverage Areas Systems Covered: Engine, Transmission, Chassis, Electrical System, Suspension, Brakes, Fuel System, Cooling System, Exhaust System, Bodywork, Troubleshooting, Maintenance, Specifications Page Count Page Count: Hundreds of pages (specific count not provided, but described as comprehensive) Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Overhaul: Complete engine disassembly, inspection, repair, and reassembly procedures for the 200cc two-stroke engine. Transmission Service: Detailed instructions for gearbox maintenance, clutch service, and troubleshooting transmission issues. Chassis And Suspension: Procedures for fork and shock absorber service, linkage maintenance, frame inspection, and wheel bearing replacement. Electrical Diagnostics: Wiring diagrams, troubleshooting guides for ignition, lighting, and charging systems, as well as component testing. Brake System Maintenance: Guidance on brake pad replacement, caliper service, master cylinder maintenance, and bleeding procedures. Fuel And Carburetion: Detailed information on carburetor adjustment, cleaning, jetting, and fuel system component inspection. Frame And Bodywork: Repair procedures for plastic body panels, seat, fuel tank, and frame components. Procedures Included Routine Maintenance: Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, and spark plug service. Troubleshooting Guides: Systematic approaches to diagnosing and resolving common operational problems and failures. Major Repairs: Instructions for significant component overhauls and replacements, including engine rebuilds. Component Disassembly Reassembly: Step-by-step guides for taking apart and putting back together all major motorcycle systems. Engine Tuning: Basic tuning advice, carburetor jetting, and exhaust modification considerations. Wheel And Tire Service: Information on tire changes, wheel balancing, and spoke tensioning. Diagnostic Charts: Flowcharts and tables to systematically diagnose common problems. Technical Depth Depth Of Information: Comprehensive factory-level detail suitable for professional technicians and experienced DIY mechanics. Torque Specifications: Precise torque values for all critical fasteners. Clearances And Tolerances: Detailed specifications for engine component clearances, bearing tolerances, etc. Wiring Diagrams: Full electrical system schematics for troubleshooting and repairs. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution for clear reproduction of text and diagrams. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Likely features searchable text within the PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, Single Cylinder Displacement: 192.7 cc (11.77 cu in) Bore X Stroke: 62.5 mm x 62.4 mm (2.46 in x 2.46 in) Cooling System: Liquid-cooled Carburetor: Keihin PWK 39 Performance Horsepower Approx: ~40 hp @ 8,500 rpm (Estimate, official figures vary) Torque Approx: ~35 Nm @ 7,500 rpm (Estimate, official figures vary) Fuel System Fuel Type: Unleaded gasoline with 2-stroke oil pre-mix Fuel Ratio: 1:40 or 1:50 (recommended by KTM) Ignition System Ignition Type: Digital CDI ignition system 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-disc clutch, hydraulically operated Features Gear Ratios: Specific ratios available in manual, typically focused on off-road performance. Transmission Oil Spec: KTM recommends specific gearbox oil, often a SAE 80W/90 API GL-4. 📐 Dimensions Exterior Wheelbase: Approx. 1470 mm (57.9 in) Ground Clearance: Approx. 350 mm (13.8 in) Weights Dry Weight: Approx. 104 kg (229 lbs) Fuel Tank Capacity: Approx. 9 liters (2.4 US gal) 🛡️ Safety Features Ratings Safety Certification: Not applicable for off-road competition motorcycles in the same way as street vehicles. Active Features Braking System: Hydraulic disc brakes front and rear. Brembo components often used. Passive Features...