🏷️ Basic Information Identification Make: KTM Model: 200 EXC Model Years Covered: 1999, 2000, 2001, 2002, 2003 Codes Engine Code Prefix: KTM 200 EXC 👋 Introduction Market Position Segment: Off-road, Enduro motorcycle. Competitive Analysis Competitors: Competed against models from Yamaha (YZ250, WR250), Honda (CR250, XR250), Suzuki (RM250, DR-Z250), and Kawasaki (KX250, KLX250) in its era. Key Features Brand Reputation: KTM is renowned for its high-performance, off-road focused motorcycles with strong European engineering. Model Attributes: The 200 EXC is characterized by its lightweight chassis, potent two-stroke engine, and agile handling, making it a formidable competitor in enduro and trail riding. 📋 Manual Details Coverage Areas Coverage Scope: Comprehensive service, repair, and workshop instructions. Page Count Estimated Page Count: 300-500 pages (typical for this model and year range) Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Top-end rebuild (cylinder, piston, rings, head), bottom-end rebuild (crankshaft, connecting rod, bearings), valve clearance adjustment, timing chain inspection and replacement, cooling system service. Fuel System: Carburetor disassembly, cleaning, and adjustment (likely Keihin or Mikuni), fuel filter replacement, fuel line inspection. Ignition System: Spark plug replacement and gap setting, CDI unit testing, ignition coil inspection. Exhaust System: Exhaust pipe and muffler inspection, gasket replacement. Transmission And Drivetrain: Clutch operation and adjustment, gearbox disassembly and reassembly, gear inspection, chain and sprocket wear assessment, lubrication. Suspension Front: Fork oil change, seal replacement, internal component inspection and service, spring preload adjustment (if applicable). Suspension Rear: Shock absorber service and adjustment, linkage bearing inspection and lubrication, swingarm bearing service. Brakes Front: Brake caliper overhaul, brake pad replacement, brake fluid flush and bleeding, disc inspection. Brakes Rear: Brake caliper overhaul, brake pad replacement, brake fluid flush and bleeding, disc inspection. Electrical System: Wiring diagrams, lighting system troubleshooting, battery maintenance and testing, starter motor inspection, charging system (stator, regulator/rectifier) testing. Cooling System: Radiator inspection and cleaning, coolant flush and refill, water pump service, thermostat operation. Frame And Bodywork: Frame inspection for cracks or damage, fairing removal and installation, seat servicing, handlebar and control lever adjustment/replacement. Procedures Included Routine Maintenance: Oil and filter change, air filter cleaning/replacement, chain adjustment and lubrication, brake inspection, tire pressure checks, general bolt torque checks. Troubleshooting: Systematic diagnostic procedures for common starting, running, and electrical issues. Component Rebuilds: Detailed step-by-step instructions for engine, transmission, suspension, and brake component overhauls. Adjustments: Carburetor jetting, clutch and throttle cable free play, suspension settings. Special Tools: Identification and usage of specialized tools required for specific procedures. Technical Depth Depth: Comprehensive from basic maintenance to full engine and chassis rebuilds, including detailed specifications and torque values. 📊 Manual Specifications File Format Digital Format: PDF (Portable Document Format) Print Quality Readability: High-resolution scanned pages, ensuring clarity of text and diagrams. Searchable text functionality is likely present. Binding Type Binding: N/A (Digital Download) Paper Type Paper Quality: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke Displacement: 193 cc (approx.) Bore X Stroke: 62.5 mm x 65 mm (typical for this displacement) Cooling System: Liquid-cooled Cylinder Configuration: Single-cylinder Power Output: Approx. 35-40 HP (varies by specific tune and year) Torque Output: Data typically not specified in owner's manuals, but significant for its class. Compression Ratio: Typically around 8.5:1 to 9.0:1 Fuel System Carburetor Type: Keihin PWK 36 or similar Fuel Type: Unleaded gasoline, minimum 91 octane (RON+MON)/2 Fuel Mixture: Pre-mix (manual will specify oil-to-fuel ratio, typically 40:1 or 50:1). 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-plate clutch, hydraulically operated. Features Gear Ratios: Specific ratios will be detailed in the manual. Final Drive: Chain drive (O-ring sealed) 📐 Dimensions Exterior Length: Approx. 2170 mm (typical) Width: Approx. 810 mm (typical) Height: Approx. 1230 mm (typical) Wheelbase: Approx. 1480 mm (typical) Weights Dry Weight: Approx. 105 kg (typical) Fuel Tank Capacity: Approx. 8 liters (typical) Oil Capacity Engine: For 2-stroke, typically refers to transmission oil capacity. Manual will specify for gearbox. Coolant Capacity: Manual will specify precise capacity. 🛡️ Safety Features Ratings Safety Certifications: As a competition-oriented off-road motorcycle, primarily designed for closed-course use, traditional automotive safety ratings (e.g., NHTSA, Euro NCAP) are not applicable. Compliance with noise and emissions regulations for off-road vehicles would be relevant. Active Features Braking System: Hydraulic disc brakes front and rear for effective stopping power in off-road conditions. Passive Features Ergonomics: Designed for rider control and comfort during demanding off-road riding, including handlebar position and footpeg placement. 💡 Technology Features Infotainment Infotainment System: None (typical for off-road motorcycles of this era). Focus is on performance and functionality. Driver Assistance Assistance Systems: None. This is a pure off-road machine focused on rider input. Connectivity Connectivity Features: None. 🔧 Maintenance Service Intervals Engine Oil Change: Refer to manual, typically every 10-15 hours of riding for a 2-stroke. Air Filter Cleaning: Refer to manual, often...