This manual covers the 200 EXC, a lightweight two-stroke, single-cylinder off-road competition motorcycle produced between 1999 and 2010. Renowned for its agility, strong power-to-weight ratio, and competitive off-road capability, the 200 EXC has been a popular choice for riders seeking a capable yet manageable machine for various off-road disciplines. Its design emphasizes performance and durability, reflecting a strong heritage in off-road racing. This comprehensive Factory Service Repair Manual provides detailed information essential for the maintenance, troubleshooting, and repair of your 200 EXC. It covers all major systems, including the powertrain, chassis, brakes, and electrical components, with specific procedures for routine servicing, adjustments, diagnostics, and complete rebuilds. This manual is an indispensable resource for owners, mechanics, and technicians aiming to maintain the optimal performance and longevity of the 200 EXC. 🏷️ 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...