The 200 XC-W, produced between 1999 and 2010, is a distinguished off-road motorcycle renowned for its lightweight design and potent two-stroke performance, engineered for aggressive trail riding and competitive enduro use. As a product of an Austrian manufacturer, celebrated for its off-road racing heritage, the 200 XC-W embodies a balance of power and rider control within its displacement class. Its robust chromoly steel frame and suspension components are designed to withstand demanding terrain, making it a capable machine for enthusiasts seeking performance and agility. This comprehensive workshop service and repair manual provides detailed guidance for the maintenance, troubleshooting, and repair of the 200 XC-W models from 1999 to 2010. Covering essential systems such as the engine, transmission, fuel, cooling, suspension, brakes, and chassis, the manual offers step-by-step procedures for everything from routine maintenance and scheduled servicing to complete engine rebuilds and suspension overhauls. It includes critical technical specifications, torque values, wiring diagrams, and diagnostic flowcharts, serving as an indispensable resource for owners and technicians aiming to preserve the optimal performance and longevity of their vehicle. 🏷️ Basic Information Identification Make: KTM Model: 200 XC-W Year Range Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Codes Manual Product Name: KTM 200 XC-W 1999-2010 Workshop Service Manual for Repair PDF Download 👋 Introduction Market Position Segment: Off-Road/Enduro Motorcycle Target Audience: Enthusiasts and owners of KTM 200 XC-W models for maintenance, repair, and restoration. Competitive Analysis Positioning: The 200 XC-W was positioned as a lightweight, agile, and potent off-road machine, offering a balance of power and usability in its displacement class. Key Features Vehicle Focus: Designed for aggressive trail riding and competitive enduro use, emphasizing performance and rider control. 📋 Manual Details Coverage Areas Manual Type: Workshop Service Manual / Repair Manual Language: English (Assumed based on typical market availability) Format: PDF Download Page Count Page Count: 280 Manual Specifications File Format: PDF Print Quality: High-resolution scans suitable for printing and digital viewing. Binding Type: N/A (Digital Download) Paper Type: N/A (Digital Download) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete engine disassembly, assembly, inspection, and repair procedures for the 200cc two-stroke engine. Engine Electrical: Ignition system, stator, CDI unit, wiring diagrams, troubleshooting electrical faults. Fuel System: Carburetor disassembly, cleaning, adjustment, jetting information, fuel pump (if applicable). Cooling System: Radiator, hoses, water pump, coolant specifications and replacement. Transmission: Gearbox disassembly, inspection, assembly, clutch operation, and maintenance. Suspension Front: Front fork (WP Suspension) disassembly, seal replacement, oil levels and specifications, damping adjustments. Suspension Rear: Rear shock absorber (WP Suspension) service, linkage maintenance, spring preload and damping adjustments. Brakes Front: Brake caliper maintenance, pad replacement, master cylinder service, bleeding procedures, fluid specifications. Brakes Rear: Brake caliper maintenance, pad replacement, master cylinder service, bleeding procedures, fluid specifications. Wheels And Tires: Wheel bearing inspection and replacement, tire pressure recommendations, rim maintenance. Chassis And Frame: Frame inspection, steering head bearing service, footpeg and handlebar mounting. Bodywork: Plastic body panel removal and installation, seat maintenance. Exhaust System: Expansion chamber and muffler inspection and maintenance. Procedures Included Routine Maintenance: Pre-ride checks, oil changes (two-stroke premix/injection), air filter cleaning/replacement, chain maintenance. Scheduled Maintenance: Detailed service intervals for engine, transmission, suspension, and chassis components. Troubleshooting: Diagnostic flowcharts for common problems related to engine performance, starting issues, electrical faults, and drivetrain. Engine Rebuild: Piston replacement, ring replacement, cylinder inspection, crankshaft and bearing service, seal replacement. Suspension Overhaul: Complete fork and shock absorber disassembly, cleaning, reassembly, and fluid replenishment. Clutch Service: Clutch plate replacement, spring inspection, and adjustment procedures. Brake System Repair: Bleeding, pad and rotor replacement, caliper seal replacement, master cylinder overhaul. Electrical Diagnostics: Wiring harness inspection, component testing (CDI, stator), fault finding. Torque Specifications: Detailed torque values for all critical fasteners throughout the motorcycle. Technical Depth Depth: Comprehensive, covering everything from basic maintenance to complete engine and chassis overhauls, suitable for both home mechanics and professional technicians. ⚙️ Engine Specifications Primary Engine Engine Type: Two-stroke, single-cylinder Displacement: 193 cc (approximate, actual may vary slightly) Bore X Stroke: Typically 64 mm x 60 mm (Verify specific model year) Cooling System: Liquid-cooled Carburetor: Keihin PWK 38 (Commonly equipped, specific size may vary) Ignition: Digital CDI Performance Horsepower Estimate: Approx. 38-42 HP (Varies by year and tuning, specific figures not in product data) Torque Estimate: Not specified in product data, but characteristic of high-revving two-strokes. Fuel System Fuel Type: Unleaded gasoline with 2-stroke oil (pre-mix or injection) Oil Mixture Ratio: Typically 1:40 or 1:50 (Refer to manual for exact specification and oil type) 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Features Clutch Type: Wet multi-disc clutch (Hydraulically operated) Gear Ratios: Specific gear ratios are detailed within the manual, crucial for performance tuning. 📐 Dimensions Exterior Frame: Chromoly steel central tube frame Weights Dry Weight: Approx. 94 kg (207 lbs) (Varies by year, exact figure in manual) Fuel Tank Capacity:...