The 200 EXC and 200 XC-W models represent a significant offering in the competition enduro motorcycle segment. These 2012 models are characterized by their lightweight, high-performance 2-stroke engines, renowned agile handling, and premium suspension components, embodying a 'Ready to Race' philosophy. Built for demanding off-road conditions, these motorcycles are designed to provide a raw, engaging riding experience, making them a popular choice for enduro enthusiasts and off-road riders. Their robust construction and focus on performance have earned them accolades in the off-road community. This comprehensive Service Repair Workshop Manual provides detailed guidance for the maintenance and repair of the 2012 200 EXC / 200 XC-W. It covers all essential aspects, including complete engine service, transmission and clutch work, fuel system adjustments, ignition system diagnostics, cooling system maintenance, and exhaust system care. Additionally, the manual offers in-depth procedures for front and rear suspension service, braking system overhauls, electrical system troubleshooting, frame and bodywork, and wheel and tire maintenance. Owners and technicians will find detailed instructions for routine maintenance, troubleshooting common issues, rebuild procedures, and assembly/disassembly, along with crucial technical specifications and safety guidelines. 🏷️ Basic Information Identification Make: KTM Model: 200 EXC / 200 XC-W Year: 2012 Product Type: Service Repair Workshop Manual Format: PDF 👋 Introduction Market Position Category: Competition Enduro Motorcycle Target Audience: Off-road riders, enduro enthusiasts, mechanics, and DIY owners Competitive Analysis Competitors: Husqvarna TE 250, Beta RR 2T, Yamaha WR250R, Honda CRF250X Key Features Engine Type: Lightweight, high-performance 2-stroke engine Suspension: Premium WP suspension components (USD forks and PDS rear shock) Handling: Renowned for agile handling and KTM's 'Ready to Race' philosophy Durability: Built for demanding off-road conditions Manual Value Value Proposition: Enables owners to perform all necessary maintenance and repairs, saving time and money 📋 Manual Details Coverage Areas Coverage: Complete Factory Service Repair Workshop Manual Page Count Page Count: Unknown (typical for digital manuals, often extensive) Manual Type Manual Type: Service Repair Workshop Manual Language Language: English Format File Format: PDF 📖 Manual Coverage Systems Covered Engine Service: Complete engine disassembly, assembly, tuning, and troubleshooting Transmission Service: Gearbox inspection, repair, clutch service, and fluid specifications Fuel System: Carburetor adjustment and overhaul (Keihin PWK 36), fuel lines, and tank maintenance Ignition System: Ignition timing, coil inspection, spark plug specifications, and troubleshooting Cooling System: Radiator, fan, water pump, and coolant specifications and service Exhaust System: Exhaust pipe and silencer inspection, maintenance, and re-packing procedures Suspension Front: WP USD forks (e.g., WP 4860 MXMA CC) - disassembly, seal replacement, oil levels, and damping adjustments Suspension Rear: WP PDS shock absorber - disassembly, seal replacement, oil, and charging pressure specifications Braking System Front: Brake caliper, master cylinder, disc, pad inspection, replacement, and bleeding procedures Braking System Rear: Brake caliper, master cylinder, disc, pad inspection, replacement, and bleeding procedures Electrical System: Wiring diagrams, lighting, battery, starter motor, and charging system diagnostics Frame And Bodywork: Frame inspection, subframe, plastics, seat, and handlebar mounting Wheels And Tires: Spoke tensioning, rim maintenance, tire replacement, and balancing Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, and lubrication schedules Troubleshooting: Diagnostic procedures for common performance issues, starting problems, and component failures Rebuild Procedures: Detailed step-by-step guides for engine and suspension component overhauls Assembly Disassembly: Comprehensive instructions for removing and installing all major vehicle components Specifications Data: Torque values, clearances, fluid capacities, and part numbers Technical Depth Depth: Comprehensive (covers all aspects from basic maintenance to complete engine rebuilds) 📊 Manual Specifications File Format File Type: Portable Document Format (PDF) Print Quality Quality: High-resolution scans of original factory documentation Binding Type Binding: N/A (Digital Download) Paper Type Paper: N/A (Digital Download) Searchability Text Search: Likely text-searchable (depends on original PDF quality) Accessibility Access Method: Instant Download ⚙️ Engine Specifications Primary Engine Engine Type: 2-stroke, single-cylinder, reed valve induction, with exhaust control (power valve) Displacement: 193 cc (11.77 cu in) Bore X Stroke: 62.5 mm x 65 mm (2.46 in x 2.56 in) Cooling System: Liquid-cooled Lubrication: Premix (fuel/oil mixture) or Autolube system (depending on specific sub-model variant) Compression Ratio: Approx. 8.2:1 (for EXC, may vary slightly for XC-W) Performance Horsepower Approx: Approx. 35-40 HP (at crankshaft, rider dependent) Torque Approx: Not officially published by KTM, but substantial for its displacement Fuel System Carburetor: Keihin PWK 36 Fuel Type: Unleaded gasoline (min. 95 RON recommended) Engine Codes Engine Prefix: Likely begins with '625' or similar KTM engine family code 🔧 Transmission Standard Transmission Type: 6-speed, constant mesh Clutch: Wet multi-disc clutch, hydraulically operated (Magura) Gear Ratios: Specific ratios detailed in the manual (e.g., 1st: 32/13, 2nd: 28/16, 3rd: 25/18, 4th: 23/20, 5th: 22/21, 6th: 19/22) Features Shifting Mechanism: Foot-operated shift lever Fluid Specifications Transmission Oil: KTM recommends Motorex Top Speed 15W/50 or equivalent SAE 10W/40 or 10W/50 API SG-CCMC G-4 motorcycle oil Fluid Capacity Transmission Oil Capacity: Approx. 0.75 Liters (0.79 US qt.) 📐 Dimensions...