🏷️ Basic Information Identification Make: KTM Model: 200 EXC Generation Production Years: 1999-2010 👋 Introduction Market Position Vehicle Segment: Off-road, Enduro, Motocross Target Audience: Enthusiast riders, amateur racers, and those seeking a capable lightweight off-road machine. Competitive Analysis Key Competitors: Yamaha WR200, Honda CR250 (though larger displacement), Suzuki RM-Z250, Kawasaki KX250 (2-stroke variants). Key Features Handling: Renowned for agile and precise handling, characteristic of KTM's off-road prowess. Performance Focus: Emphasis on lightweight construction and a potent 2-stroke engine for spirited off-road riding. Durability: Built with KTM's reputation for robust construction suitable for demanding off-road conditions. 📋 Manual Details Coverage Areas Vehicle Models Covered: KTM 200 EXC (1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010) Page Count Estimated Page Count: 500+ Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine overhaul, top-end and bottom-end rebuilds, piston, rings, cylinder, crankshaft, connecting rod, bearings, seals, gaskets, cooling system (radiator, fan, hoses, coolant). Fuel System: Carburetor (Keihin PWK series) disassembly, cleaning, adjustment, jetting, fuel pump (if applicable), fuel lines, fuel tank. Transmission: Gearbox disassembly, inspection, and reassembly; clutch operation, service, and replacement; gear shift mechanism. Electrical System: Ignition system (CDI, spark plug, coil), lighting system, wiring diagrams, battery, stator, regulator/rectifier, starter motor (if electric start equipped). Suspension: Front forks (WP USD) overhaul, seal replacement, oil level and type specification, damping adjustments. Rear shock absorber service, spring preload adjustment, rebound damping adjustment. Brakes: Hydraulic disc brakes (front and rear), caliper service, pad replacement, brake fluid type and bleeding procedures, master cylinder overhaul. Chassis And Frame: Frame inspection, swingarm removal and service, linkage systems (if applicable), bearings, bushings. Bodywork And Controls: Seat removal, plastics, handlebars, controls (throttle, clutch lever), footpegs, exhaust system removal and installation. Procedures Included Maintenance: Routine service intervals, oil changes, filter replacements (air, oil if applicable), chain maintenance, brake checks, tire pressure, spark plug replacement, decarbonization. Troubleshooting: Diagnostic guides for common running problems, starting issues, electrical faults, suspension noises, brake performance. Repair: Step-by-step instructions for component removal, installation, and repair for all major systems. Diagnostics: Explains diagnostic procedures for identifying faults using visual inspection, sound analysis, and basic measurement tools. Technical Depth Level Of Detail: Comprehensive, suitable for DIY enthusiasts and professional mechanics. Covers everything from basic maintenance to complete engine and transmission rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchability: Text-searchable PDF for quick information retrieval. Print Quality Printability: Printable pages for easy reference in the workshop. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder, liquid-cooled Displacement: 193 cc (approximately, varies slightly by year) Bore X Stroke: 62.5 mm x 65 mm (typical for this era) Cooling System: Liquid-cooled with fan assist Ignition System: Digital CDI (Capacitor Discharge Ignition) Lubrication: Pre-mix or automatic oil injection (depending on specific sub-model or year) Performance Horsepower Estimated: 35-40 hp (estimated, actual figures vary) Torque Estimated: 25-30 Nm (estimated, actual figures vary) Fuel System Carburetor Type: Keihin PWK (e.g., PWK 35) Fuel Type: Unleaded gasoline (minimum 95 RON recommended) Fuel Mixture Ratio: Typically 1:40 or 1:50 with a quality 2-stroke oil, consult manual for precise ratio. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate clutch, hydraulically operated Features Gear Ratios: Specific gear ratios available within the manual for each gear. Transmission Oil Type: API GL-4 or GL-5 gear oil (e.g., Motul Gear 300 75W-90 or similar, consult manual for exact specification). Transmission Oil Capacity: Approximately 0.7-0.8 Liters (consult manual for exact capacity and level check procedure). 📐 Dimensions Exterior Wheelbase: Approx. 1480 mm (may vary slightly by year) Seat Height: Approx. 960 mm (may vary slightly by year) Weights Dry Weight: Approx. 100-105 kg (may vary slightly by year) Fuel Tank Capacity: Approx. 8-10 Liters (may vary slightly by year) Wheels And Tires Front Wheel Size: 21 inches Rear Wheel Size: 18 inches Front Tire Size: e.g., 80/100-21 Rear Tire Size: e.g., 100/100-18 🛡️ Safety Features Ratings Safety Certification: Not applicable for off-road use in the same way as street-legal vehicles; designed for off-road competition and recreational use. Active Features Braking System: Hydraulic disc brakes front and rear for effective stopping power. Suspension Control: Adjustable suspension components allow tuning for terrain and rider preference, aiding stability. Passive Features Frame Construction: Robust steel frame designed for off-road abuse and rider protection. Handguards: Standard handguards to protect levers and rider's hands from roost and impacts. 💡 Technology Features Infotainment Infotainment System: N/A (Pure off-road machine with minimal electronic features focused on performance). Driver Assistance Rider Aids: No electronic rider aids; focus is on rider skill and direct machine feedback. Connectivity Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change Interval: Every 10-15 hours of riding or annually, whichever comes...