The 200 EXC is a celebrated off-road motorcycle known for its lightweight agility and potent 2-stroke engine, designed for enthusiasts and competitors in enduro and trail riding. Produced across several model years from 1999 to 2006, this model embodies a strong heritage in motorsport, offering a robust and performance-oriented package. Its engineering emphasizes a powerful 193 cc liquid-cooled engine featuring a power valve system for optimized delivery, coupled with a 6-speed transmission and a chromoly steel trellis frame for exceptional handling and durability in demanding terrains. This comprehensive Service Repair Workshop Manual provides detailed guidance for the maintenance, repair, and troubleshooting of 200 EXC models from 1999 through 2006. It covers all essential systems, including engine overhauls, transmission servicing, chassis and suspension work, brake system maintenance, and electrical diagnostics. The manual is an indispensable resource for owners and technicians, offering step-by-step instructions, technical specifications, fluid recommendations, and preventative maintenance schedules to ensure the vehicle’s optimal performance and longevity. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC Production Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006 Codes Chassis Codes: KTM EXC 200 (specific chassis codes per year may vary, consult manual for precise VIN decoding) 👋 Introduction Market Position Segment: Enduro / Off-Road Motorcycle Target User: Enthusiast riders, off-road competitors, adventure riders seeking reliable performance and self-sufficiency. Competitive Analysis Key Competitors: Yamaha WR200, Suzuki DR-Z250, Honda CR250R (though the EXC 200 is a 2-stroke, it competes in displacement class). Key Features Vehicle Focus: Lightweight, agile, potent 2-stroke engine optimized for technical off-road riding, trail riding, and competitive enduro use. Manual Value Proposition: Essential resource for maintaining peak performance, diagnosing issues, and performing repairs on the KTM 200 EXC, maximizing its lifespan and usability. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, repair, and maintenance for KTM 200 EXC models from 1999-2006. Page Count Estimated Page Count: Likely 300-600 pages (typical for a full workshop manual of this era). Manual Type Type: Service Repair Workshop Manual Language Language: English (assumed based on product description fragment). Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Full engine overhaul, top-end rebuild (cylinder, piston, head), bottom-end service (crankshaft, bearings, seals), valve adjustment, cooling system, lubrication system, exhaust system. Transmission: Gearbox disassembly and reassembly, clutch service, shift mechanism, gear oil specifications and change intervals. Chassis: Frame inspection and repair, suspension (forks, shock absorber - including seals, oil, and valving), steering system, swingarm, linkages. Brakes: Hydraulic brake system service (front and rear), caliper overhaul, master cylinder maintenance, bleeding procedures, pad replacement, rotor inspection. Electrical: Wiring diagrams, ignition system troubleshooting, lighting circuits, battery maintenance, starter motor, charging system (stator, regulator/rectifier). Fuel System: Carburetor service and tuning (likely Keihin PWK type), fuel tank, fuel lines, petcock. Cooling System: Radiator service, coolant specifications, water pump, thermostat operation. Bodywork: Panel removal and installation, seat, fenders, fairings, graphics. Procedures Included Preventative Maintenance: Scheduled maintenance tasks, lubrication points, filter changes (air, oil), chain and sprockets care, spark plug replacement. Troubleshooting: Diagnostic flowcharts, common problems and their solutions, symptom-based troubleshooting guides. Repair: Step-by-step repair instructions for all major mechanical and electrical components, including torque specifications and special tool requirements. Rebuilds: Detailed instructions for complete engine, transmission, and suspension component rebuilds. Adjustments: Carburetor jetting, idle speed, clutch cable, brake levers, suspension sag. Technical Depth Depth: Full factory-level technical detail, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic fluid changes to complete engine teardowns and rebuilds. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Printability: High resolution, suitable for printing individual pages or the entire manual. Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Type: 2-Stroke Single Cylinder Displacement: 193 cc (approx.) Bore X Stroke: Specific to KTM 200 EXC models of this era (refer to manual for exact figures, e.g., 62.5 mm x 65 mm is common for similar KTM models). Cooling System: Liquid-cooled Compression Ratio: Specific to model year, typically around 8.4:1 to 8.6:1 for 2-strokes of this era. Performance Horsepower: Approximately 35-40 HP (actual figures vary by model year and tuning). Torque: Approximately 25-28 Nm (actual figures vary). Fuel System Carburetor: Likely Keihin PWK 38mm or similar, with specific jetting provided in the manual. Fuel Type: Unleaded gasoline (minimum 91 RON/87 AKI), pre-mix with 2-stroke oil. Engine Components Cylinder Head Design: Removable cylinder head for piston access and combustion chamber service. Power Valve System: Features an exhaust power valve system for improved low-end torque and top-end power delivery. 🔧 Transmission Standard Type: 6-speed manual transmission Clutch Type: Hydraulically operated wet multi-plate clutch Features Gear Ratios: Specific gear ratios for each of the 6 speeds will be detailed in the manual. Critical for off-road performance tuning. Fluid Specifications Gearbox Oil Type: Specific KTM recommended or API...