The 200 XC-W, produced between 1999 and 2010, is a lightweight, high-performance off-road motorcycle engineered for enduro racing and demanding trail riding. Building on a rich motorsports heritage, this model features a compact, liquid-cooled 2-stroke LC2 engine, delivering approximately 40-45 horsepower through a 6-speed transmission. Its Austrian-engineered chassis, typically equipped with WP suspension and a robust chromoly steel frame, is renowned for exceptional agility and handling characteristics. Designed for off-road capability, the 200 XC-W boasts long-travel suspension, powerful hydraulic disc brakes, and an ergonomic design focused on rider control and comfort in challenging terrain. This comprehensive Factory Service Repair Manual, written in English and spanning over 500 pages, provides essential information for the maintenance and repair of your 200 XC-W from 1999 to 2010. It covers all critical systems, including the engine, transmission, chassis, electrical system, fuel, cooling, brakes, wheels, and bodywork. Detailed procedures for preventive maintenance, troubleshooting common issues, engine rebuilds, suspension setup, and carburetor tuning are included, alongside clear wiring diagrams. This manual is an indispensable resource for owners and technicians alike, ensuring the optimal performance, reliability, and longevity of the motorcycle through accurate guidance and detailed technical specifications. 🏷️ Basic Information Identification Make: KTM Model: 200 XC-W Production Years: 1999-2010 Codes Engine Code General: LC2 Generation Platform Notes: The KTM 200 XC-W represents a specific evolution within KTM's off-road motorcycle lineup during this period, focusing on a smaller displacement, agile, and competitive package for enduro racing and trail riding. 👋 Introduction Market Position Segment: Lightweight, high-performance off-road motorcycle (Enduro/Cross Country). Competitive Analysis Competitors General: Competes with other small-displacement 2-stroke off-road bikes from brands like Yamaha (YZ250), Honda (CR250), Suzuki (RM250), and Kawasaki (KX250) in their respective classes, though often positioned for specific enduro applications. Key Features Engine Type: Compact 2-stroke engine known for its snappy power delivery and light weight. Chassis Design: Austrian-engineered chassis, typically featuring WP suspension and a strong chromoly steel frame, emphasizing agility and handling. Offroad Capability: Designed specifically for off-road riding, with long-travel suspension, knobby tires, and a durable build. 📋 Manual Details Coverage Areas Covered Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Page Count: 500+ Manual Type Manual Type: Factory Service Repair Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Complete engine disassembly, inspection, repair, and reassembly for the 2-stroke LC2 engine. Transmission: Gearbox, clutch, and shift mechanism maintenance and repair. Chassis: Frame, swingarm, suspension (forks and shock), and steering components. Electrical System: Ignition, lighting, charging system, wiring diagrams, and component testing. Fuel System: Carburetor (Keihin PWK likely), fuel tank, petcock, and fuel lines. Cooling System: Radiator, coolant hoses, and thermostat (if applicable). Brakes: Hydraulic front and rear brake systems, including calipers, master cylinders, lines, and bleeding procedures. Wheels Tires: Wheel bearing maintenance, spoke tensioning, and tire changing. Bodywork: Fairings, seat, fenders, and plastics removal and installation. Procedures Included Preventive Maintenance: Regular service intervals for oil changes, filter replacements, chain adjustment, and bolt torque checks. Troubleshooting: Diagnostic guides for common problems related to engine performance, electrical issues, and starting difficulties. Repair Procedures: Step-by-step instructions for component replacement and overhaul. Engine Rebuild: Detailed instructions for top-end (piston, rings, cylinder) and bottom-end (crankshaft, bearings) rebuilds. Suspension Setup: Information on adjusting suspension sag, compression, and rebound damping. Carburetor Tuning: Jetting recommendations, idle speed adjustment, and float height setting. Wiring Diagrams: Comprehensive and clearly illustrated wiring schematics. Technical Depth Depth: Comprehensive, covering everything from routine maintenance to complete engine and chassis overhauls, with detailed diagnostic procedures. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-resolution, suitable for printing all pages. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type: N/A (Digital Download) Searchability Searchable Text: Likely searchable text within the PDF for quick information retrieval. ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, liquid-cooled Displacement: 193 cc Bore X Stroke: 62.5 mm x 65 mm (typical for this era LC2) Compression Ratio: Approx. 8.5:1 (typical, may vary by year/tune) Ignition: Digital CDI Performance Horsepower: Approximately 40-45 HP (estimated, peak output) Torque: Approximately 20-22 lb-ft (estimated) Fuel System Carburetor Type: Keihin PWK 38mm (common for this model) Fuel Type: Unleaded gasoline with 2-stroke oil pre-mix (typically 40:1 or 50:1 ratio, consult manual) Oil Type: High-quality 2-stroke synthetic or semi-synthetic engine oil. 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Optional Optional Transmissions: N/A (standard manual transmission) Features Clutch Type: Hydraulic, multi-plate wet clutch Final Drive: Chain drive (520 pitch common) Gear Ratios: Specific gear ratios will be detailed within the manual. Transmission Fluid: Specialized gearbox oil (e.g., Motorex Gear Oil 75W/80 or equivalent, consult manual for specific KTM recommendation). 📐 Dimensions Exterior Length: Variable, but typically around 83 inches (2100 mm). Width: Variable, but typically around 32 inches (820 mm) at handlebars. Height: Variable, but typically...