The 200 XC-W, produced between 1999 and 2010, is a highly capable off-road motorcycle renowned for its lightweight construction, agile handling, and potent 2-stroke engine performance. This model is engineered for demanding enduro and cross-country riding, emphasizing durability and responsiveness across varied terrains. Its aggressive styling and focus on competition have made it a favored choice for riders seeking a robust and exhilarating off-road experience, reflecting a strong heritage in motorsports. This Service Repair Manual provides comprehensive guidance for the maintenance and repair of the 200 XC-W. It covers essential areas including complete engine overhauls, transmission servicing, chassis systems such as suspension and brakes, and the electrical system. The manual details routine maintenance procedures, troubleshooting common issues, and step-by-step repair instructions for all major components. It is an indispensable resource for owners, mechanics, and technicians aiming to ensure the optimal performance, reliability, and longevity of their 200 XC-W. 🏷️ Basic Information Identification Make: KTM Model: 200 XC-W Codes Engine Code General Mention: Specific engine codes for individual years and potential variations may be detailed within the manual, but the primary identifier is the 200cc XC-W engine configuration. 👋 Introduction Market Position Market Position: The KTM 200 XC-W is positioned as a potent off-road competition or recreational enduro motorcycle, known for its lightweight chassis, agile handling, and strong performance in its displacement class. This manual targets owners and technicians who require in-depth knowledge for maintenance and repair. Competitive Analysis Competitive Analysis: During its production run, the 200 XC-W competed against similar displacement off-road bikes from brands like Yamaha (e.g., WR250), Honda (e.g., CR250, though displacements varied), and Husqvarna. Its unique blend of power delivery and KTM's renowned chassis dynamics made it a distinct choice. Key Features Key Features Of Vehicle: Lightweight, aggressive styling, powerful 2-stroke engine (prior to later 4-stroke models), advanced suspension, focused off-road capability, durable construction for demanding conditions. 📋 Manual Details Coverage Areas Coverage Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Page Count: Not explicitly stated in product info, but typical comprehensive service manuals of this era and scope range from 300 to 600+ pages. Manual Type Manual Type: Service Repair Manual Language Language: English (Assumed, typical for service manuals of this nature) Format Format: PDF 📖 Manual Coverage Systems Covered Engine System: Complete engine overhaul, top-end (cylinder, piston, valves), bottom-end (crankshaft, connecting rod, bearings), lubrication system, cooling system (if applicable to the specific model variant), fuel system (carburetor service, jetting, fuel lines), ignition system, exhaust system. Transmission System: Clutch operation and service, gearbox disassembly and reassembly, shift mechanism, lubrication. Chassis Systems: Suspension (forks, rear shock absorber), steering system, braking system (hydraulic calipers, master cylinders, brake lines, pads, rotors), wheels, hubs, bearings, drive chain and sprockets, electrical system (wiring diagrams, lighting, battery, ignition switch). Electrical System: Wiring diagrams, component location, battery maintenance, charging system, ignition system, lighting, starter (if electric start equipped). Fuel System: Carburetor disassembly, cleaning, inspection, jetting specifications, fuel pump (if applicable), fuel lines, petcock. Cooling System: Radiator inspection and cleaning, hose replacement, thermostat function (if equipped), coolant type and capacity. Procedures Included Maintenance Procedures: Regular servicing, oil changes, filter replacements (air, oil), spark plug maintenance, valve clearance adjustment, chain adjustment and lubrication, brake bleeding, coolant flush (if liquid-cooled). Troubleshooting Diagnostics: Diagnosis of common problems, error codes (if applicable), electrical troubleshooting, mechanical issues identification. Repair Overhaul: Step-by-step instructions for disassembly, inspection, repair, and reassembly of all major components, including engine rebuilds, carburetor tuning, suspension servicing, and brake system repairs. Engine Tuning: Carburetor jetting adjustments for various conditions (altitude, temperature), power valve adjustment and cleaning, ignition timing checks. Suspension Servicing: Front fork seal replacement, oil level and type, damping adjustments, rear shock absorber service, spring preload adjustments. Wheel And Tire Service: Tire changing, tube replacement, wheel balancing, spoke tensioning, wheel bearing replacement, rim specifications. Technical Depth Technical Depth: Comprehensive, covering everything from routine maintenance and adjustments to full engine and transmission rebuilds, electrical system diagnostics, and suspension overhaul. Suitable for both novice and experienced mechanics. Diagnostic Tools: While primarily mechanical, the manual will cover basic electrical diagnostic procedures using multimeters and visual inspection. Specific diagnostic tools like data loggers or OBD-II scanners are not applicable to this era of off-road motorcycle. 📊 Manual Specifications File Format File Format Details: PDF format, typically searchable text for ease of navigation. High-resolution scans for clear diagrams and illustrations. Print Quality Print Quality: High-quality digital reproduction of original factory service manuals, ensuring clarity of diagrams, schematics, and text. Binding Type Binding Type: N/A (Digital PDF format) Paper Type Paper Type: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke Single Cylinder Displacement: 193 cc (Approximately, specific figures may vary slightly by year) Bore X Stroke: Typically around 62.5 mm x 65 mm (Verify within manual for exact specification) Cooling...