Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010
Chassis Designation:
Not explicitly provided, typically 'EXC' or similar for off-road models
Segment:
Competition Enduro / Off-Road Motorcycle
Target Audience:
KTM 200 MXC owners, mechanics, and enthusiasts seeking in-depth technical information for maintenance, repair, and restoration.
Competitors:
Models from Husqvarna, Yamaha (WR250), Honda (CRF250X/RX), Suzuki (RM-Z250), Kawasaki (KX250X) during the covered period.
Value Proposition:
Provides authoritative, factory-level diagnostic and repair procedures essential for maintaining the performance and longevity of the KTM 200 MXC.
Manual Advantage:
Offers detailed technical specifications, torque values, and exploded diagrams often missing in generic repair guides.
Primary Coverage:
Complete factory service and repair procedures for the KTM 200 MXC
Secondary Coverage:
Maintenance schedules, troubleshooting guides, electrical diagrams, torque specifications, component overviews
Estimated Page Count:
500-800 pages (typical for comprehensive factory service manuals of this era)
Type:
Factory Service Repair Manual
Language:
English (Assumed based on typical factory manuals for international markets)
Engine:
Top-end overhaul (cylinder, piston, head), bottom-end rebuild (crankshaft, connecting rod, bearings), valve adjustment (if applicable for 4-stroke), carburetor tuning and rebuild, cooling system, lubrication system
Transmission:
Clutch operation and service, gearbox disassembly and reassembly, shift mechanism, gear oil specifications
Electrical System:
Ignition system troubleshooting and repair, lighting, charging system (stator, regulator/rectifier), wiring diagrams, battery maintenance
Chassis And Suspension:
Front fork service (seal replacement, oil change, valving), rear shock absorber service and adjustment, wheel bearing maintenance, steering head bearing service, frame inspection
Brakes:
Front and rear brake system service (pad replacement, caliper overhaul, master cylinder rebuild), hydraulic fluid specifications, bleeding procedures, rotor inspection
Fuel System:
Fuel tank maintenance, fuel lines, fuel pump (if applicable), carburetor cleaning and adjustments
Exhaust System:
Muffler and pipe inspection, gasket replacement
Cooling System:
Radiator service, coolant type and capacity, hose inspection and replacement
Maintenance:
Oil change intervals and specifications, filter replacement, chain adjustment, spark plug replacement, air filter cleaning
Troubleshooting:
Diagnostic procedures for common issues, symptom-based troubleshooting guides
Repair:
Step-by-step instructions for component removal, installation, and repair
Assembly Disassembly:
Complete breakdown and reassembly of major vehicle components
Depth:
Comprehensive: Covers everything from routine maintenance and adjustments to complete engine and transmission rebuilds, electrical system diagnostics, and suspension overhauls.
Type:
2-Stroke, Single-Cylinder
Displacement:
193 cc (approximately, specific to 200cc designation)
Bore X Stroke:
Exact specifications would be detailed in the manual, typically around 62.5 mm x 65 mm for a 200cc 2-stroke.
Cooling System:
Liquid-cooled
Carburetor:
Likely Keihin PWK type, with specific model number in manual (e.g., PWK 38).
Horsepower:
Estimated 35-40 HP (typical for this class and era), precise figures in manual.
Torque:
Not typically published for this class, but detailed engine torque values will be present in the manual.
Fuel Type:
Unleaded gasoline, recommended octane rating specified in manual.
Fuel Mixture:
2-stroke oil/gasoline mixture; specific ratio (e.g., 40:1 or 50:1) will be in the manual.
Premix Oil Spec:
Specific 2-stroke oil type and grade (e.g., JASO FD, ISO-L-EGD) will be listed.
Type:
6-speed constant mesh
Clutch:
Hydraulically operated, multi-plate wet clutch.
Gear Ratios:
Specific gear ratios for each of the 6 speeds will be provided in the manual.
Final Drive:
Chain drive, with specific chain size (e.g., 520) and adjustment procedures.
Transmission Oil:
Type and capacity of transmission/gearbox oil will be specified, e.g., SAE 10W/30 or 10W/40 motorcycle gear oil.
Wheelbase:
Typically around 1450-1480 mm (57-58 inches), exact value in manual.
Ground Clearance:
High for off-road use, typically 330-360 mm (13-14 inches), exact value in manual.
Dry Weight:
Approximately 105-115 kg (231-253 lbs), exact value in manual.
Fuel Tank Capacity:
Typically around 7-9 liters (1.8-2.4 gallons), exact value in manual.
Crash Test Ratings:
N/A (Off-road motorcycle, not subject to automotive crash testing standards)
Braking System:
Hydraulic disc brakes front and rear. Specifics on caliper type and rotor diameter in manual.
Suspension Features:
Upside-down front forks (e.g., WP USD), PDS rear shock absorber with adjustable preload and damping. Specific settings and service procedures in manual.
Lighting:
Headlight, taillight/brake light, potentially indicators depending on homologation.
Engine Oil Change:
Refer to manual, typically every 15-25 hours of riding for 2-stroke engines or per riding season.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours or as needed).
Spark Plug Replacement:
Refer to manual, typically every 20-40 hours or based on condition.
Top End Rebuild:
Varies greatly with usage and maintenance, but often recommended between 80-150 hours for competitive use.
Engine Oil:
2-stroke premix oil meeting specific standards (e.g., JASO FD, ISO-L-EGD), ratio provided in manual.
Transmission Oil:
SAE 10W/30 or 10W/40 motorcycle gear oil.
Coolant:
Ethylene glycol-based antifreeze mixed with distilled water, typically 50/50 ratio. Specific type in manual.
Brake Fluid:
DOT 4 hydraulic brake fluid.
Common Wear Items:
Piston rings, spark plugs, clutch plates, wheel bearings, fork seals, pivot bearings (swingarm, linkage), chain and sprockets.
2-Stroke Specific:
Carburetor jetting sensitivity to altitude/temperature, reed valve wear, exhaust packing deterioration.
Electrical:
Stator output degradation over time, regulator/rectifier failure (less common on older 2-strokes with simpler systems).
Heritage:
KTM is renowned for its off-road and motorsports pedigree, with a strong focus on performance and 'Ready to Race' philosophy.
Mx Evolution:
The 200 MXC (often part of the EXC range) was a popular model for its blend of manageable power and agility, suitable for enduro and trail riding. Over its production run, it likely received minor updates to suspension, carburetion, and cosmetics.
Manufacturing Origin:
Austria (KTM's primary manufacturing location)
