Model Variant:
2-stroke Enduro Motorcycle
Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Chassis Code Range:
Likely includes specific chassis codes for each model year, but not explicitly stated in product info.
Segment:
Performance Off-Road Motorcycle (Enduro/Motocross)
Target Audience:
Owners and mechanics of KTM 200 EXC motorcycles requiring detailed repair and maintenance information.
Competitors Of Vehicle:
Other 125-250cc 2-stroke off-road bikes from brands like Husqvarna, Yamaha (YZ series), Honda (CR series), Suzuki (RM series), Kawasaki (KX series).
Engine Type:
2-stroke, liquid-cooled, single-cylinder engine known for its potent power delivery and lightweight design.
Suspension:
Typically equipped with high-quality WP suspension components offering excellent adjustability and performance for off-road use.
Utility:
Essential resource for DIY maintenance, repair, and troubleshooting, enabling owners to keep their motorcycles in optimal condition and reduce reliance on professional services.
Primary Focus:
Engine Service and Repair
Additional Coverage:
Likely includes sections on routine maintenance, troubleshooting, and potentially basic chassis adjustments related to the engine.
Estimated Page Count:
N/A (PDF format, exact page count not specified in product info)
Type:
Service Repair Manual
Language:
English (Assumed based on typical market)
Engine Components:
Cylinder, Piston, Crankshaft, Connecting Rod, Crankcase, Cylinder Head, Valves, Ignition System (CDI), Carburetor (likely Keihin PWK), Exhaust System, Cooling System (liquid-cooled), Lubrication System (pre-mix or separate oil injection)
Transmission Components:
Gearbox Internals, Clutch System (hydraulic or cable operated), Shift Mechanism, Gear Ratios (specifics depend on manual content)
Electrical System:
Wiring Diagrams (likely focused on engine-related circuits), Ignition Timing, Alternator, Battery Charging System
Routine Maintenance:
Oil Changes (if applicable for gearbox), Spark Plug Replacement, Air Filter Cleaning/Replacement, Chain Adjustment, Valve Clearance Check/Adjustment (if applicable, though 2-strokes typically don't have them in the traditional sense, may refer to exhaust port timing adjustments), Carburetor Cleaning and Tuning
Major Repairs:
Top-End Rebuild (Piston, Rings, Cylinder), Bottom-End Rebuild (Crankshaft, Bearings, Seals), Clutch Overhaul, Transmission Rebuild, Ignition System Troubleshooting and Repair, Carburetor Overhaul
Troubleshooting:
Diagnostic Procedures for Common Issues (e.g., starting problems, poor running, misfiring), Fault Finding Charts, Diagnostic Codes (if applicable)
Depth:
Comprehensive (Expected to cover from basic maintenance to complete engine and gearbox overhaul, including component specifications and disassembly/assembly procedures).
Detail Level:
Detailed step-by-step instructions, torque specifications, tolerances, special tool requirements, and diagrams/illustrations.
Engine Type:
2-Stroke, Liquid-Cooled, Single Cylinder
Displacement:
193 cc (approximate, specific to 200 EXC)
Bore X Stroke:
Typical for this era's 200cc 2-strokes, specific dimensions would be in manual.
Cooling System:
Liquid Cooling (Radiator and Fan)
Fuel Delivery:
Carburetor (likely Keihin PWK 36 or similar)
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Lubrication:
Pre-mix fuel or Automatic Oil Injection (KTM's versions varied, check specific model year in manual)
Horsepower:
Estimated 35-40 HP (at crankshaft, varies by year and specific tuning)
Torque:
Not typically published as prominently as HP for this class, but significant for its size.
Carburetor Model:
Likely Keihin PWK 36mm or similar, exact model to be confirmed in manual.
Fuel Type:
Unleaded Gasoline (91-98 Octane recommended, check manual for specifics and pre-mix ratio if applicable)
Power Valve System:
Likely features an electronically or mechanically controlled exhaust power valve for optimized torque and horsepower across the rev range.
Wheelbase:
Approximately 1470-1490 mm (varies by model year, check manual)
Seat Height:
Approximately 920-940 mm (varies by model year, check manual)
Dry Weight:
Approximately 95-105 kg (varies by model year and equipment, check manual)
Safety Certification:
CE Certified (typical for European market bikes, details would be in manual)
Braking System:
Hydraulic Disc Brakes (Front and Rear), Brembo calipers commonly used.
Tire Specifications:
Off-road specific tires, typically 80/100-21 front and 100/90-18 rear. Specific recommendations in manual.
Dashboard:
Basic LCD or digital display showing speed, odometer, trip meter, and potentially engine hour meter. Advanced infotainment not applicable to this era/type of bike.
Rider Aids:
None (this is a pure, analog off-road machine focused on rider input).
Bluetooth Usb:
Not applicable to this model.
Oil Change Gearbox:
Every 15-20 hours of riding or annually. Specific recommendation in manual.
Piston Ring Replacement:
Recommended every 50-75 hours of riding for optimal performance, or based on compression testing. Critical for 2-stroke longevity, detailed in manual.
Top End Rebuild:
Depending on usage and maintenance, a full top-end rebuild (piston, rings, cylinder inspection/hone) might be considered around 100-150 hours.
Air Filter Cleaning:
Frequently, especially after dusty rides. Every 5-10 hours.
Gearbox Oil:
KTM recommends specific transmission oil, often a 10W/40 or 10W/50 semi-synthetic or synthetic motorcycle gear oil. SAE 75W/80W GL-4 is also commonly used. Check manual for exact spec and capacity.
Coolant:
High-quality ethylene glycol-based coolant with corrosion inhibitors. Mix 50/50 with distilled water. Specific type/brand may be recommended in manual.
2-Stroke Oil:
Premium 2-stroke synthetic oil designed for high-performance off-road engines. Ratio (if pre-mix) or specific injection oil to be confirmed in manual.
Power Valve Sticking:
Can occur due to carbon buildup, requiring cleaning. Manual will detail inspection and cleaning procedures.
Carburetor Jetting:
May require adjustments based on altitude, temperature, and modifications. Manual will provide baseline jetting and tuning guidance.
Clutch Wear:
Clutch plates and springs can wear over time, especially under hard use. Manual covers inspection and replacement.
Engine Vibration:
Characteristic of 2-strokes; maintaining proper engine balance is key. Manual covers engine component torque specifications for proper reassembly.
Manufacturer:
KTM, an Austrian manufacturer renowned for its off-road racing pedigree and performance-oriented motorcycles.
200 Exc Development:
The 200 EXC was positioned as a lightweight, agile, and powerful 2-stroke option bridging the gap between 125cc and larger displacement enduro bikes, offering a potent blend of power and manageable weight.
Manufacturing Location:
Austria (primarily)
