The 200 MXC, produced from 1999 to 2003, is a lightweight and agile off-road competition motorcycle renowned for its potent 2-stroke engine and performance-oriented design. As part of the esteemed EXC/MXC series, this model embodies the dedication to off-road racing excellence, offering riders a competitive edge in motocross and enduro disciplines. Its engineering prioritizes agility and power delivery, making it a formidable machine for demanding off-road environments. This comprehensive workshop repair service manual is designed to be an indispensable resource for owners and technicians alike. It covers all variants of the 200 MXC for the specified production years, offering detailed procedures for engine disassembly and assembly, fuel and exhaust system maintenance, transmission and drivetrain servicing, and suspension and brake system repairs. The manual also includes routine maintenance schedules, troubleshooting guides for common issues, and in-depth coverage of electrical systems and chassis components, ensuring the optimal performance and longevity of your vehicle. 🏷️ Basic Information Identification Make: KTM Model: 200 MXC Model Code: MXC 200 Generation Generation: First Generation (KTM EXC/MXC Series) Codes Production Years Covered: 1999, 2000, 2001, 2002, 2003 👋 Introduction Market Position Vehicle Category: Off-road Competition/Enduro Motorcycle Target Audience: Motocross and Enduro riders, mechanics, enthusiasts Competitive Analysis Competitive Segment: Lightweight off-road competition bikes, often competing with models from Yamaha, Honda, Suzuki, and Husqvarna in the 125-250cc 2-stroke class. Key Features Vehicle Philosophy: Lightweight, agile, performance-oriented off-road machine with a potent 2-stroke engine. Manual Value Proposition: Essential resource for maintaining, troubleshooting, and repairing the KTM 200 MXC, crucial for preserving its performance and longevity. 📋 Manual Details Coverage Areas All Models Covered: Yes (All 200 MXC variants for the specified years) Page Count Estimated Page Count: 300-400 pages (typical for comprehensive workshop manuals of this era) Manual Type Manual Type: Workshop Repair Service Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine System: Complete disassembly, assembly, inspection, and tuning of the 2-stroke engine. Fuel System: Carburetor tuning, jetting, float bowl adjustment, fuel line inspection, fuel filter replacement. Cooling System: Radiator maintenance, coolant replacement, fan operation (if applicable), hose inspection. Exhaust System: Expansion chamber inspection, muffler packing, sealing. Transmission System: Gearbox disassembly, inspection, lubrication, clutch operation, adjustment, and replacement. Drivetrain System: Chain and sprocket inspection, adjustment, and replacement, rear hub maintenance. Suspension System Front: Fork disassembly, seal replacement, oil type and level, spring inspection, valving. Brake System Front: Caliper overhaul, pad replacement, fluid bleeding, disc inspection, master cylinder service. Wheel And Tire: Spoke tensioning, rim inspection, bearing maintenance, tire pressure, mounting. Electrical System: Ignition system troubleshooting, lighting, wiring diagrams, battery maintenance. Chassis And Frame: Frame inspection for damage, steering head bearing service, subframe checks. Bodywork And Plastics: Fairing removal and installation, seat maintenance, graphics. Suspension System Rear Rear Suspension System: Monoshock absorber inspection, service, linkage maintenance, bearing checks. Brake System Rear Rear Brake System: Caliper overhaul, pad replacement, fluid bleeding, disc inspection, master cylinder service. Procedures Included Routine Maintenance: Oil changes, filter replacements, chain lubrication, spark plug checks, air filter cleaning. Troubleshooting: Diagnostic guides for common starting, running, and performance issues. Engine Rebuild: Top-end and bottom-end rebuild procedures, piston ring installation, cylinder honing. Suspension Service: Complete fork and shock absorber service, including oil and seal changes. Brake System Repair: Bleeding, caliper rebuilding, master cylinder service. Clutch Adjustment And Replacement: Cable adjustment, clutch plate replacement. Electrical Diagnostics: Wiring diagram interpretation, component testing. Carburetor Rebuild And Jetting: Detailed steps for carburetor disassembly, cleaning, reassembly, and performance tuning. Technical Depth Depth Of Coverage: Comprehensive: Covers everything from basic adjustments to complete engine and chassis overhauls. Diagnostic Capability: Advanced: Includes troubleshooting charts and specific diagnostic procedures. Rebuild Instructions: Detailed step-by-step rebuild instructions with torque specifications. 📊 Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Print Quality Print Quality Recommendation: High-resolution for clear diagrams and text. Binding Type Binding Type: N/A (Digital Download) Paper Type Paper Type Recommendation: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: 2-Stroke Single-Cylinder Displacement: 193 cc (approx.) Bore X Stroke: Typical: 62.5 mm x 65 mm (specific value to be confirmed in manual) Cooling System: Liquid-Cooled Power Valuation Metric: Horsepower (HP) Performance Estimated Horsepower: Around 35-40 HP (varies with tuning and specific year) Estimated Torque: Significant low-to-mid range torque characteristic of 2-strokes Fuel System Carburetor Type: Typically Keihin PWK (e.g., PWK 38) Fuel Type Recommendation: Unleaded gasoline, 95-98 RON, mixed with 2-stroke oil at specified ratio (e.g., 1:30 to 1:50). Reed Valve System: Yes, typically Moto Tassinari VForce or similar reed blocks. 🔧 Transmission Standard Transmission Type: 6-Speed Manual Features Clutch Type: Wet Multi-Plate Clutch 📐 Dimensions Exterior Wheelbase: Approx. 1460-1480 mm (146-148 cm) Weights Dry Weight: Around 100-105 kg (220-230 lbs) Fuel Tank Capacity: Approx. 10-12 Liters (2.6-3.2 Gallons) 🛡️ Safety Features Ratings Safety Ratings: N/A (Off-road competition vehicle, not subject to standard road safety...