This manual covers the 200 XC, a high-performance off-road motorcycle produced between 1999 and 2010. Embodying the "Ready to Race" philosophy, the 200 XC is renowned for its lightweight construction, potent liquid-cooled two-stroke engine, and agile handling, making it a formidable machine in the competitive Enduro and Cross-Country segments. Its design emphasizes power-to-weight ratio and rider control, a testament to Austrian engineering heritage and consistent development in off-road racing. This comprehensive Service Repair Workshop Manual provides detailed guidance for maintaining and repairing your 200 XC across its production years. It covers essential areas including engine overhaul, transmission service, chassis and suspension maintenance, brake system care, and electrical system diagnostics. The manual offers step-by-step repair instructions, routine maintenance procedures, troubleshooting guides for common issues, and critical technical specifications, ensuring owners and technicians have the necessary information to keep the motorcycle in optimal condition. 🏷️ Basic Information Identification Make: KTM Model: 200 XC Generation Production Years: 1999-2010 👋 Introduction Market Position Segment: Off-road motorcycle, Enduro/Cross-Country segment. Competitive Analysis Competitors: Yamaha WR250F, Honda CRF250X, Suzuki RM-Z250, Kawasaki KX250F (though this KTM is a 2-stroke, it competes in the displacement class for off-road performance). Key Features Design Philosophy: KTM's renowned 'Ready to Race' philosophy, emphasizing lightweight construction, powerful two-stroke engines, and agile handling for competitive off-road use. Engine Type: Two-stroke, single-cylinder, liquid-cooled, known for its strong power-to-weight ratio. 📋 Manual Details Coverage Areas Model Years Covered: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Page Count: Varies by specific year and edition, but typically 300-500 pages for a comprehensive service manual. Manual Type Type: Service Repair Workshop Manual Language Language: English Format Format: PDF Download 📖 Manual Coverage Systems Covered Engine: Detailed overhaul, troubleshooting, component testing, lubrication, cooling system, fuel system (carburetor tuning and diagnosis), exhaust system. Transmission: Clutch operation, gearbox disassembly and assembly, shift mechanism, lubrication, troubleshooting. Chassis And Suspension: Front fork service (Öhlins/WP), rear shock absorber service, linkage system, steering head bearings, swingarm maintenance. Brakes: Brake system service, hydraulic components, pad replacement, fluid bleeding, caliper maintenance, master cylinder. Electrical System: Wiring diagrams, lighting, ignition system, charging system (stator, regulator/rectifier), battery maintenance, troubleshooting electrical faults. Bodywork And Plastics: Fairing removal and installation, seat, fuel tank, fenders, general bodywork repair. Procedures Included Maintenance: Routine checks, oil changes, filter replacements, chain adjustment, spark plug service, pre-ride inspections. Troubleshooting: Diagnostic guides for common problems, symptom-based troubleshooting charts. Repair: Step-by-step instructions for component disassembly, repair, and reassembly. Technical Depth Depth: Comprehensive, covering from basic maintenance to full engine and transmission rebuilds, including detailed torque specifications and component clearances. 📊 Manual Specifications File Format Quality: High-resolution PDF, typically optimized for digital viewing and printing. Searchability: Searchable text content allows for quick access to specific information. Print Quality Printability: Designed to be printable, allowing users to create physical copies of sections or the entire manual. Binding Type Binding: N/A (Digital PDF Download) Paper Type Paper Type: N/A (Digital PDF Download) ⚙️ Engine Specifications Primary Engine Type: Liquid-cooled, 2-stroke, single-cylinder with reed valve induction and PowerJet carburetor system (often Keihin PWK). Displacement: Approximately 193 cc (bore x stroke typically around 66 mm x 57.4 mm). Bore X Stroke: Approx. 66.0 mm x 57.4 mm Compression Ratio: Typically around 12.0:1 to 13.5:1 (subject to specific model year). Ignition: Digital electronic ignition (CDI). Performance Horsepower: Estimated 40-45 HP (at crankshaft, varies by year and tuning). Torque: Estimated 35-40 Nm (at crankshaft, varies by year). Fuel System Carburetor: Keihin PWK 36mm (common) with PowerJet technology for improved high-RPM performance. Fuel Type: Unleaded gasoline, minimum 95 octane recommended. Requires 2-stroke oil pre-mix or oil injection system. Lubrication System: Premix fuel/oil or automatic oil injection system (depending on specific model year and region). Cooling System Type: Liquid-cooled via radiator and fan. 🔧 Transmission Standard Type: 6-speed constant mesh gearbox. Features Clutch: Hydraulically operated multi-plate wet clutch. Final Drive: Chain drive (RK or similar, typically 520 pitch). 📐 Dimensions Exterior Wheelbase: Approx. 1470-1490 mm (57.9-58.7 inches). Seat Height: Approx. 940-960 mm (37.0-37.8 inches). Weights Dry Weight: Approx. 105-110 kg (231-243 lbs). Fuel Tank Capacity: Approx. 8-9 Liters (2.1-2.4 US gallons). 🛡️ Safety Features Ratings Safety Certification: Not typically safety rated in the same manner as street-legal vehicles; designed for off-road use. Active Features Braking System: Hydraulic disc brakes front and rear (e.g., Brembo calipers). Passive Features Frame Construction: Chromium-molybdenum steel trellis frame for rigidity and strength. 💡 Technology Features Infotainment Features: N/A (Designed for performance and off-road use; no typical infotainment systems). Driver Assistance Features: N/A (No electronic rider aids like ABS or traction control on these models). Connectivity Features: N/A 🔧 Maintenance Service Intervals Oil Change: Every 10-15 hours of riding or annually. Use specified 2-stroke engine oil (e.g., Motul 800 2T Factory Line Off Road). Air Filter Cleaning: After every few rides, especially in dusty conditions. Use...