This manual covers the 200 EXC, a highly regarded 2-stroke, single-cylinder motorcycle renowned for its potent power delivery and agile handling. Produced between 1999 and 2010, the 200 EXC embodies the 'Ready to Race' philosophy, offering robust construction and performance tailored for demanding enduro and off-road competition and recreation. Its key features include a high-performance engine, typically equipped with advanced suspension for exceptional adjustability, and a durable chromoly steel trellis frame that contributes to its precise feedback and maneuverability. This model is celebrated for its durability and its lineage rooted in extensive off-road racing success. The purpose of this comprehensive Service and Repair Manual is to provide detailed guidance for the maintenance, repair, and troubleshooting of the 200 EXC. It covers a wide array of systems, including complete engine mechanicals, fuel and ignition systems, transmission and clutch, suspension, brakes, and the electrical system. Within its 300+ pages, owners, mechanics, and technicians will find step-by-step procedures for scheduled maintenance, engine rebuilds, suspension overhauls, carburetor tuning, and electrical diagnostics. This English-language manual ensures efficient access to essential information for keeping the 200 EXC in optimal working condition. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC Codes Engine Variant: 2-stroke, single-cylinder 👋 Introduction Market Position Segment: Enduro / Off-Road Competition and Recreation Competitive Analysis Competitors: Yamaha WR250, Honda CR250/CRF250, Suzuki RM250, Kawasaki KX250 (during its 2-stroke era) Key Features Engine Type: High-performance 2-stroke engine known for its potent power delivery and lightweight design. Suspension: Typically equipped with high-quality WP suspension components, offering excellent adjustability and performance. Handling: Renowned for its agile and precise handling characteristics, a hallmark of KTM off-road motorcycles. Durability: Built for demanding off-road use, with robust components designed for longevity under harsh conditions. 📋 Manual Details Coverage Areas Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Pages: 300+ Manual Type Type: Service and Repair Manual Language Language: English Format Format: PDF 📖 Manual Coverage Systems Covered Engine Mechanical: Complete disassembly, inspection, and reassembly of engine components (cylinder, piston, crankshaft, connecting rod, bearings, seals, gaskets, etc.) Fuel System: Carburetor service and tuning (e.g., Keihin PWK), fuel lines, fuel tank, petcock Ignition System: CDI unit, ignition coil, spark plug, timing adjustment Cooling System: Radiator, cooling fan, water pump, coolant flow, thermostat Transmission And Clutch: Gearbox, shift drum, shift forks, clutch assembly (plates, springs, basket), hydraulic clutch system Exhaust System: Exhaust pipe, silencer maintenance, power valve operation and adjustment Suspension: Front fork (WP USD) service, seal replacement, oil levels, rear shock absorber service Brakes: Hydraulic brake systems (front and rear), caliper service, master cylinder, brake fluid replacement, pad replacement, bleeding procedures Electrical System: Wiring diagrams, lighting, charging system (stator, regulator/rectifier), battery maintenance, starter system (if applicable to specific sub-models) Chassis And Frame: Frame inspection, steering head bearing service, swingarm bearing service Wheels And Tires: Spoke tensioning, wheel bearing replacement, tire fitting and removal Procedures Included Scheduled Maintenance: Detailed procedures for routine checks, oil changes, filter replacements, spark plug replacement, chain adjustment, and general inspections at specified intervals. Troubleshooting: Diagnostic charts and procedures for identifying and resolving common mechanical and electrical issues. Engine Rebuild: Step-by-step instructions for complete engine disassembly, cleaning, inspection, part replacement (e.g., piston kits, crankshafts), and reassembly with torque specifications. Suspension Overhaul: Instructions for fork seal replacement, bushing replacement, and rear shock absorber rebuild. Carburetor Tuning: Guidance on jetting, idle speed adjustment, and general carburetor maintenance for optimal performance. Clutch Adjustment: Procedures for adjusting clutch cable or hydraulic system for proper engagement and disengagement. Electrical Diagnosis: Fault finding for ignition, charging, and lighting systems using wiring diagrams. Brake System Maintenance: Bleeding, pad replacement, caliper service, and master cylinder maintenance. Technical Depth Depth: Comprehensive: Covers everything from basic owner maintenance checks to complete engine and chassis overhauls, including detailed specifications and troubleshooting guides. 📊 Manual Specifications File Format File Type: Digital PDF Searchability: Text-searchable PDF for quick access to information Print Quality Resolution: High-resolution scans for clear text and diagrams Binding Type Binding: N/A (Digital Format) Paper Type Paper Type: N/A (Digital Format) ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder, liquid-cooled, reed valve induction Displacement: 193 cc (approximately) Bore X Stroke: 62.5 mm x 65 mm (typical for this era) Compression Ratio: Varies by year, typically around 8.0:1 to 8.5:1 Cylinder Head: Single spark plug, liquid-cooled cylinder head Lubrication: Premix fuel-oil or automatic oil injection (depending on specific sub-model year) Performance Horsepower Estimate: Approximately 30-35 HP (at crankshaft, depending on tuning and year) Torque Estimate: Approximately 20-23 lb-ft (at crankshaft, depending on tuning and year) Fuel System Carburetor Type: Keihin PWK 36 (common for this model) Fuel Type: Unleaded gasoline, 95-98 octane recommended (RON) Ignition System Ignition Type: Digital CDI with variable ignition timing Engine Internals Piston Type: Single-ring, lightweight piston Connecting Rod: High-strength, forged connecting rod 🔧 Transmission Standard...