This manual covers the 200 EXC, a liquid-cooled, 2-stroke single-cylinder Enduro/Off-road motorcycle manufactured for model years 1999 through 2003. Renowned for its lightweight construction, agile handling, and potent engine performance, the 200 EXC offers a compelling balance of power and manageability for off-road enthusiasts. Its design prioritizes a high power-to-weight ratio, characteristic of the brand's racing pedigree and commitment to delivering 'Ready to Race' machines. The 200 EXC was positioned within the enduro lineup as a capable option for demanding terrain, competing effectively against other off-road motorcycles of its displacement class. This comprehensive Service Repair Manual is specifically focused on the engine and related components of the 200 EXC. It provides detailed guidance on engine disassembly and reassembly, component inspection, troubleshooting common faults, and performing essential maintenance. The manual covers critical systems including the top and bottom end, lubrication, cooling, fuel delivery, and ignition. It is an indispensable resource for owners, mechanics, and technicians, offering in-depth procedures, technical specifications, torque values, and diagnostic charts to ensure the optimal performance and longevity of the vehicle's engine. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC Model Variant: Engine Codes Engine Codes: Likely based on existing KTM single-cylinder engine architecture for the era, specific codes not detailed in product info but assumed to be consistent within the 1999-2003 timeframe. Generation Generation Identifier: Model years 1999-2003 👋 Introduction Market Position Vehicle Segment: Enduro / Off-road motorcycle, targeting riders seeking performance and agility in demanding terrain. Competitive Analysis Key Competitors Era: Competed with other 200cc to 250cc off-road machines from brands like Husqvarna, GasGas, and potentially smaller-displacement models from Japanese manufacturers in specific markets. Key Features Ktm 200 Exc Selling Points: Known for its lightweight construction, potent 2-stroke engine performance, agile handling, and KTM's reputation for racing pedigree. The 200 EXC offered a balance of power and manageability for off-road enthusiasts. Engine Type Advantage: The 2-stroke engine provides a simpler design with a high power-to-weight ratio compared to 4-stroke engines of similar displacement. 📋 Manual Details Coverage Areas Manual Scope: Specifically focused on the Engine of the KTM 200 EXC for the stated model years. Troubleshooting Section: Dedicated section for diagnosing starting problems, running issues, oil leaks, and performance anomalies. Page Count Estimated Page Count: Typically 200-400 pages for a comprehensive engine service manual of this era, though exact count not specified. Manual Type Manual Classification: Service Repair Manual Language Language Of Manual: English (presumed, standard for most repair manuals of this type unless otherwise stated) Format Delivery Format: PDF 📖 Manual Coverage Systems Covered Engine Systems: Top end (cylinder head, valves, camshafts), bottom end (crankshaft, connecting rod, pistons), lubrication system, cooling system, fuel delivery (carburetor specific), ignition system, exhaust system components directly related to the engine. Chassis Related Engine Components: Engine mounting points, exhaust system mounting, airbox and intake boot, fuel tank and petcock interface. Procedures Included Repair And Maintenance Procedures: Engine disassembly and reassembly, component inspection and measurement, troubleshooting common engine faults, carburetor tuning and overhaul, cooling system maintenance, oil change procedures, spark plug replacement, valve adjustment, timing procedures, seal and gasket replacement. Wiring And Ignition: Ignition system troubleshooting, stator testing, CDI unit diagnostics, spark plug gap and type, wiring diagrams for engine-specific circuits. Technical Depth Diagnostic And Rebuild Capability: Comprehensive, covering everything from routine maintenance to complete engine rebuilds, including detailed specifications for component tolerances and torque values. Diagnostic Charts: Likely includes detailed troubleshooting flowcharts for common engine issues, helping diagnose problems systematically. 📊 Manual Specifications File Format Document Format: Portable Document Format (PDF) Searchability: PDF format is typically searchable if the original document was text-based, greatly improving ease of use. Print Quality Printability: Likely optimized for digital viewing and printing, with clear diagrams and text. Binding Type Physical Binding: N/A (Digital PDF format) Paper Type Physical Paper Quality: N/A (Digital PDF format) ⚙️ Engine Specifications Primary Engine Engine Type: Liquid-cooled, 2-stroke single cylinder Bore X Stroke: Likely around 64 mm x 60 mm (typical for 200cc class, specific value to be confirmed by manual) Displacement: Approximately 193 cc (actual displacement for 200 EXC) Performance Horsepower Estimate: Estimated 30-35 HP at peak, precise figure varies by tuning and year. Torque Estimate: Estimated 20-24 Nm, specific figure dependent on engine tune. Power Delivery Characteristics: Characterized by strong mid-range and top-end power, typical of a well-tuned 200cc 2-stroke performance engine. Fuel System Carburetor Type: Likely a Keihin PWK or similar high-performance 2-stroke carburetor, typically 35-38mm. Fuel Type: Unleaded gasoline, typically requires a higher octane rating (e.g., 95 RON or higher) due to 2-stroke design, and often mixed with 2-stroke oil. Lubrication Lubrication Type: Premix or Autolube (oil injection system, manual will specify which) Cooling Cooling System: Liquid-cooled via radiator and fan. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Optional Transmissions: N/A (Standard configuration for EXC models) Features Clutch Type: Hydraulically actuated,...