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KTM 200 EXC EXC SIX DAYS 1999-2006 Workshop Service Manual

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This manual covers the 200 EXC and EXC SIX DAYS models produced between 1999 and 2006. Renowned for its lightweight chassis, potent 2-stroke engine, and advanced suspension, the 200 EXC...
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Typ: Motorcycle
Anbieter:
Ktm
Art.-Nr: 72518
Stichworte: 1999 200 EXC 2000 2001 2002 2003 2004 2005 2006 EXC SIX DAYS KTM Misc Motorcycle Motorcycles
KTM 200 EXC EXC SIX DAYS 1999-2006 Workshop Service ManualKTM 200 EXC EXC SIX DAYS 1999-2006 Workshop Service ManualKTM 200 EXC EXC SIX DAYS 1999-2006 Workshop Service ManualKTM 200 EXC EXC SIX DAYS 1999-2006 Workshop Service Manual
This manual covers the 200 EXC and EXC SIX DAYS models produced between 1999 and 2006. Renowned for its lightweight chassis, potent 2-stroke engine, and advanced suspension, the 200 EXC is engineered for exceptional off-road performance and competition. The SIX DAYS variant further enhances this capability with specialized components and graphics, reflecting a strong heritage in enduro racing. This machine is designed for riders who demand agility, power, and reliability in demanding off-road environments. This comprehensive workshop service manual provides detailed guidance for the maintenance, repair, and troubleshooting of your 200 EXC / EXC SIX DAYS. It covers all essential systems, including engine overhaul, transmission, chassis, and electrical components, with step-by-step procedures, technical specifications, and torque values. Whether you are performing routine maintenance, addressing complex repairs, or seeking to understand the intricacies of your vehicle, this manual serves as an indispensable resource for owners and technicians alike.
🏷️ Basic Information
Identification
Make:
KTM
Model:
200 EXC EXC SIX DAYS
Model Variant:
SIX DAYS
Production Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Codes
Chassis Code Range:
Likely specific to generation and sub-model, consult manual for precise identification
Engine Code Range:
Likely specific to generation and sub-model, consult manual for precise identification
👋 Introduction
Market Position
Market Position:
Enduro and Off-Road Competition/Enthusiast Segment
Competitive Analysis
Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (2-stroke variants from the era)
Key Features
Key Features:
Lightweight chassis, potent 2-stroke engine, potent suspension, optimized for off-road performance, 'SIX DAYS' edition denotes specialized components and graphics from international enduro events.
📋 Manual Details
Coverage Areas
Primary Coverage:
Workshop Service Manual for Repair
Page Count
Page Count:
217
Manual Type
Manual Type:
Workshop Service Manual
Language
Language:
English (assumed, standard for most professional manuals)
Format
Format:
PDF Download
📖 Manual Coverage
Systems Covered
Engine Systems:
Engine overhaul, top-end, bottom-end, lubrication, cooling, fuel delivery, ignition, exhaust
Transmission Systems:
Gearbox, clutch, shifting mechanism, lubrication
Chassis Systems:
Frame, suspension (front and rear), steering, brakes (hydraulic), wheels, tires
Electrical Systems:
Wiring diagrams, lighting, ignition system components, battery, charging system, controls
Bodywork And Plastics:
Fairings, seat, body panels, graphics (SIX DAYS specific details likely)
Procedures Included
Maintenance Procedures:
Routine maintenance, oil changes, filter replacements, chain adjustment, brake bleeding, spark plug replacement
Repair Procedures:
Complete engine rebuild, transmission overhaul, suspension fork service, brake caliper rebuild, electrical component replacement
Troubleshooting Guides:
Diagnostic flowcharts, common problem identification and resolution
Torque Specifications:
Detailed torque values for all critical fasteners
Special Tools:
Listing and usage of specialized tools required for specific procedures
Technical Depth
Depth:
Comprehensive, covering from basic maintenance to full engine and chassis overhauls, suitable for professional mechanics and experienced DIY enthusiasts
📊 Manual Specifications
File Format
File Format:
Portable Document Format (PDF)
Print Quality
Print Quality:
High-resolution scans suitable for clear printing and digital viewing
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine
Engine Type:
2-stroke
Displacement:
193 cc (approximate for 200 EXC designation)
Bore X Stroke:
Consult manual for exact specifications (typically around 62.5 mm x 65 mm)
Cooling System:
Liquid-cooled
Performance
Horsepower:
Estimated 35-40 HP (subject to specific tuning and year)
Torque:
Consult manual for exact specifications
Fuel System
Carburetor Type:
Typically Keihin PWK (e.g., 35mm)
Fuel Type:
Unleaded gasoline with 2-stroke oil mixture (premix or autolube system)
Lubrication
Lubrication Type:
Premix or separate autolube injection system (confirm with manual)
🔧 Transmission
Standard
Transmission Type:
6-speed manual gearbox
Optional
Optional Features:
N/A (standard configuration)
Features
Clutch Type:
Wet multi-plate clutch (hydraulic actuation typical)
Final Drive:
Chain drive
📐 Dimensions
Exterior
Frame Type:
Chromoly steel, central-tube, single-cradle, perimeter frame
Wheelbase:
Consult manual for exact specifications (typically around 1460 mm)
Seat Height:
Consult manual for exact specifications (typically around 960 mm)
Weights
Dry Weight:
Consult manual for exact specifications (typically around 95-105 kg)
Fuel Tank Capacity:
Consult manual for exact specifications (typically around 8-10 Liters)
Wheels And Tires
Front Wheel Size:
21 inch
Rear Wheel Size:
18 inch
Front Tire Size:
Typically 80/100-21
Rear Tire Size:
Typically 100/100-18 or 110/100-18
Brakes
Front Brake Type:
Hydraulic disc brake, twin-piston caliper
Rear Brake Type:
Hydraulic disc brake, single-piston caliper
🛡️ Safety Features
Ratings
Safety Ratings:
N/A (Off-road motorcycles typically not subjected to road-vehicle safety rating tests like NHTSA or Euro NCAP)
Active Features
Active Safety:
Powerful hydraulic disc brakes, responsive suspension, ergonomic controls
Passive Features
Passive Safety:
Sturdy frame construction, impact-absorbing components (e.g., handlebars, levers if designed for it)
💡 Technology Features
Infotainment
Infotainment System:
N/A (Basic instrumentation: speedometer, odometer, engine hour meter, warning lights)
Driver Assistance
Driver Assistance:
N/A
Connectivity
Connectivity:
N/A
Ignition System
Ignition System Type:
Digital ignition with variable ignition timing, often CDI or similar electronic ignition
🔧 Maintenance
Service Intervals
Oil Change Interval:
Consult manual for exact intervals; typically every 10-15 hours of riding or annually.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (check manual for specific guidance).
Spark Plug Replacement:
Consult manual; typically every 20-30 hours of riding.
Top End Rebuild:
Consult manual; recommended based on operating hours (e.g., 50-100 hours for piston/rings, potentially more for cylinder).
Fluid Specifications
Engine Oil Type:
Specific 2-stroke premix oil, high quality, JASO FD or equivalent recommended. Consult manual for exact specifications and mixing ratio if applicable.
Gearbox Oil Type:
High-quality motorcycle gear oil, e.g., SAE 75W/80 or 80W/90. Consult manual for specific KTM recommendation (e.g., Motorex Gear Oil).
Coolant Type:
Ethylene glycol-based antifreeze coolant mixture. Consult manual for specific type and mixture ratio.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Known Issues
Common Issues Overview:
Potential issues common to high-performance 2-strokes of this era include jetting sensitivity, wear on clutch plates, suspension seal leaks, and regular maintenance of the power valve system.
Power Valve Maintenance:
Crucial for optimal performance. Regular cleaning and inspection for carbon buildup and proper function are essential.
Carburetor Jetting:
Requires careful attention to altitude, temperature, and humidity for optimal performance and engine longevity. Manual will provide baseline jetting specs.
📚 Vehicle History
Brand Heritage
Brand Heritage:
KTM has a strong heritage in off-road motorsports, particularly enduro and motocross, renowned for its 'Ready to Race' philosophy.
Model Evolution
Model Evolution Context:
The EXC line represents KTM's enduro offerings. The 200 EXC was a popular choice for riders seeking a powerful yet manageable 2-stroke for various off-road disciplines. The 'SIX DAYS' designation celebrates KTM's success in the International Six Days Enduro (ISDE) and typically included upgraded components like special graphics, sometimes different exhaust systems, or enhanced suspension.
Production
Production Period:
1999-2006 for this specific generation covered by the manual.
Manufacturing Location:
Austria (Primary KTM production)
🏆 Awards & Recognition
Recognitions
Brand Recognitions:
KTM has numerous awards and championships in various off-road racing disciplines, reflecting the performance and durability of their models.
Ratings
Model Ratings:
Subjective reviews and rider feedback often praised the 200 EXC for its power-to-weight ratio and handling capabilities in its class.
Certifications
Certifications:
N/A (Not applicable to this type of vehicle/manual)
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