The 200 MXC, produced between 1999 and 2003, is a high-performance off-road motorcycle renowned for its Austrian engineering and strong off-road pedigree. This model features a liquid-cooled, 2-stroke, single-cylinder engine with reed valve induction, delivering an estimated 35-40 horsepower. Its design prioritizes capability on challenging terrain, equipped with WP suspension, a chromoly steel frame, and hydraulic disc brakes for effective control and stopping power. The 200 MXC was engineered for enthusiasts and amateur racers, competing in a segment known for agile handling and robust build quality, reflecting specialization in motocross and enduro riding. This comprehensive service repair workshop manual covers the 200 MXC for the years 1999 through 2003. It provides detailed guidance on a wide range of maintenance, repair, and diagnostic procedures. Key areas include engine mechanicals, fuel and ignition systems, cooling, transmission, drivetrain, suspension, brakes, wheels, tires, electrical systems, frame, and bodywork. The manual also details scheduled maintenance, troubleshooting common issues, routine repairs, major overhauls, and specific system tuning, such as suspension adjustments and electrical diagnostics. It includes essential technical specifications, torque values, fluid types, and capacities, making it an indispensable resource for owners and technicians aiming to maintain and repair this off-road motorcycle effectively. 🏷️ Basic Information Identification Make: KTM Model: 200 MXC Model Designation: 200 MXC Vehicle Type: Off-road Motorcycle Generation Generation Code: First Generation (1999-2003) Codes Vin Code Region: WBH Engine Code Family: LC2 200 👋 Introduction Market Position Segment: Performance Off-Road / Enduro Motorcycle Target Audience: Enthusiasts, amateur racers, and riders seeking a capable off-road machine. Competitive Analysis Competitors Era: Competed against models like Yamaha YZ250, Suzuki RM250, Honda CR250 (2-stroke), and potentially early 4-stroke off-road bikes from other manufacturers. Ktm Positioning: Known for its robust, performance-oriented Austrian engineering and strong off-road pedigree. Key Features Engine Type: Liquid-cooled, 2-stroke, single-cylinder engine. Suspension Type: High-quality WP suspension (usually upside-down front forks and a linkage-driven monoshock). Frame Type: Chromoly steel frame, known for strength and flexibility. Offroad Capability: Designed specifically for motocross and off-road riding with ample ground clearance and suspension travel. 📋 Manual Details Coverage Areas Applicable Years: 1999, 2000, 2001, 2002, 2003 Page Count Estimated Page Count: Likely 300-500 pages (typical for comprehensive service manuals) Manual Type Type: Service Repair Workshop Manual Language Language: English (Assumed based on typical global distribution) Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine Mechanical: Engine disassembly, assembly, inspection, diagnosis, repair of cylinder, piston, crankshaft, connecting rod, bearings, valves, camshafts, lubrication system. Engine Fuel System: Carburetor inspection, cleaning, adjustment, jetting, fuel pump, fuel lines, fuel tank maintenance. Ignition System: Ignition coil, spark plug, stator, CDI unit, wiring, timing inspection and adjustment. Cooling System: Radiator, hoses, coolant, water pump inspection and service. Transmission: Gearbox disassembly, assembly, inspection, gear selection, shifting mechanism, clutch operation, clutch plates, springs, hydraulic actuation. Drivetrain: Chain and sprocket inspection, adjustment, replacement, rear hub, swingarm maintenance. Suspension Front: Front forks (upside-down type) disassembly, seal replacement, oil level and type, spring preload, damping adjustments, fork tube inspection. Suspension Rear: Monoshock rear suspension, linkage system, shock absorber inspection, service, tuning, rear spring replacement. Brakes Front: Brake caliper inspection, pad replacement, fluid flush, bleeding, master cylinder service, brake disc inspection. Brakes Rear: Rear brake caliper inspection, pad replacement, fluid flush, bleeding, master cylinder service, brake disc inspection. Wheels Tires: Wheel bearing inspection, replacement, spoke tensioning, tire pressure, tire replacement, rim maintenance. Electrical System: Battery maintenance, charging system, lighting (headlight, taillight, turn signals if applicable), wiring diagrams, fuse inspection, horn, starter system (if electric start equipped). Frame Chassis: Frame inspection for cracks or damage, steering head bearing service, footpeg mounts, subframe inspection. Bodywork: Fairing removal and installation, seat, fuel tank removal, fender maintenance, graphics application. Controls: Throttle cable adjustment and replacement, clutch lever and cable, brake lever, shifter adjustment. Procedures Included Scheduled Maintenance: Oil changes, filter replacement, chain lubrication and adjustment, brake checks, tire pressure checks, spark plug inspection/replacement, air filter cleaning/replacement. Troubleshooting: Diagnostic flowcharts for common problems (e.g., starting issues, poor performance, electrical faults), symptom-based problem identification. Routine Repairs: Carburetor cleaning and tuning, chain replacement, brake pad replacement, fork seal replacement, spark plug replacement, air filter service. Major Overhauls: Full engine rebuilds (top-end and bottom-end), transmission rebuilds, suspension overhauls. Electrical Diagnostics: Wiring diagram interpretation, component testing (e.g., stator, CDI), troubleshooting electrical circuits. Suspension Tuning: Fork oil level and viscosity adjustment, rear shock adjustments for compression and rebound damping. Technical Depth Depth: Comprehensive: Covers everything from basic checks and adjustments to complete engine, transmission, and suspension rebuilds, including electrical system diagnostics. Diagnostics: Detailed diagnostic procedures and troubleshooting guides for all major systems. Specifications: Includes torque specifications, clearances, fluid types and capacities, electrical tolerances, and settings. 📊 Manual Specifications File Format Format: PDF Searchability: Likely searchable text within the PDF for easy information retrieval. Print Quality Quality: High resolution, suitable for printing clear diagrams and text. Binding Type Type: N/A...