Segment:
Performance Off-Road Motorcycle (Enduro/Cross Country)
Target Audience:
Enthusiast riders, amateur racers, and professional mechanics requiring detailed repair and maintenance information.
Competitors Era:
Suzuki RM250, Yamaha YZ250, Honda CR250 (2-stroke), Husqvarna WR250, GasGas EC250 of the same period.
Brand Focus:
KTM's reputation for high-performance, race-bred machinery.
Model Advantage:
The 200 EXC offered a potent blend of 125 agility and 250 power in a lightweight package, making it a niche but highly capable machine.
Manual Value Proposition:
Provides essential technical data for maintaining and repairing a performance off-road motorcycle, crucial for its longevity and optimal function.
Engine System:
Detailed disassembly, assembly, inspection, and repair of all engine components including top-end (cylinder, piston, rings, head), bottom-end (crankshaft, connecting rod, bearings), cooling system, lubrication system, and power valve operation.
Transmission And Drivetrain:
Complete coverage of gearbox operation, clutch system (including wet multi-plate clutch), shift mechanism, chain and sprocket maintenance, and gearbox oil specifications.
Fuel System:
Carburetor (likely Keihin PWK based on era) overhaul, adjustment, jetting information, fuel lines, petcock, and tank maintenance.
Electrical System:
Wiring diagrams, ignition system (CDI, coil, spark plug), lighting, charging system (stator, regulator/rectifier), battery, and starter system (if applicable).
Suspension System:
Front fork (WP USD forks typical) disassembly, seal replacement, oil type and level specifications, damping adjustments, and rear shock absorber (WP PDS or similar) servicing and adjustments.
Braking System:
Front and rear hydraulic brake system maintenance, caliper overhaul, master cylinder service, brake fluid type and bleeding procedures, pad replacement, and rotor inspection.
Cooling System:
Radiator, hoses, water pump, and coolant specifications, bleeding procedures, and system pressure testing.
Chassis And Frame:
Frame inspection, steering head bearing service, swingarm and linkage maintenance, footpeg and lever adjustments, and general chassis component inspection.
Bodywork And Plastics:
Removal and installation of fenders, seat, fuel tank, side panels, and graphics.
Maintenance Procedures:
Regular service tasks, including oil changes, filter replacements (air and oil/screen), spark plug checks, chain adjustment, brake fluid changes, and tire pressure checks.
Troubleshooting Guides:
Systematic diagnostic procedures for common problems, including starting issues, engine performance problems, electrical faults, and suspension malfunctions.
Engine Rebuild Procedures:
Comprehensive instructions for top-end rebuilds, bottom-end overhauls, and complete engine disassembly and reassembly.
Suspension Servicing:
Detailed steps for fork seal replacement, damper rod service, and rear shock absorber rebuilds.
Electrical Diagnostics:
Fault finding based on symptoms, circuit testing, and component testing using multimeters.
Brake System Maintenance:
Bleeding procedures, caliper piston service, and master cylinder overhaul.
Carburetor Tuning And Rebuild:
Jetting recommendations, float height adjustment, and complete carburetor disassembly and cleaning.
Diagnostic Capability:
Advanced diagnostics for complex issues, including electrical system troubleshooting and performance tuning.
Repair Scope:
From basic routine maintenance to complete engine and gearbox rebuilds, including component-level repairs.
Specifications Detail:
Includes critical torque specifications, clearances, fluid levels, and diagnostic parameters for all major systems.
Wiring Diagrams Completeness:
Comprehensive and detailed wiring diagrams essential for electrical system diagnostics and repairs.
Engine Type:
Two-Stroke Single Cylinder
Bore X Stroke:
62.5 mm x 65 mm (Typical for this model)
Cooling System:
Liquid-Cooled
Power Valve System:
KTM's PowerJet or similar electronic/mechanical exhaust power valve system.
Starting System:
Kickstart
Horsepower Estimate:
Approx. 35-40 HP (at crankshaft, subject to tuning and specific year)
Torque Estimate:
Approx. 25-28 Nm (at crankshaft, subject to tuning and specific year)
Carburetor Model:
Keihin PWK 35 (Common fitment for this era)
Fuel Type:
Unleaded Premium Gasoline (95 Octane or higher recommended)
Premix Ratio:
50:1 or 40:1 (using high-quality 2-stroke racing oil, as specified in manual)
Engine Oil Change Interval:
Check and top-up before every ride. Change gearbox oil every 15-25 hours of riding or annually. (Refer to manual for precise intervals).
Air Filter Cleaning:
Clean after every 5-10 hours of riding, or more frequently in dusty conditions.
Spark Plug Inspection:
Inspect and clean/replace every 20-30 hours of riding.
Chain Lubrication Adjustment:
Lubricate chain every 500 km (300 miles) or more frequently if exposed to water/mud. Adjust tension as needed, checking for approximately 20-30mm of slack.
Coolant Type:
Ethylene Glycol based antifreeze with corrosion inhibitors (e.g., Motorex Coolant M3.0 or equivalent).
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid (KTM recommends specific grades, e.g., Motorex Brake Fluid DOT 4).
Fork Oil Type:
Specific suspension fork oil with appropriate viscosity (e.g., WP Suspension Fluid 5W, or aftermarket equivalents like Maxima, Bel-Ray). Manual will specify viscosity and volume.
Common Wear Items:
Piston rings, clutch plates, wheel bearings, steering head bearings, fork seals, and swingarm bearings are typical wear items on high-performance off-road bikes.
Power Valve Sticking:
The power valve mechanism can accumulate carbon deposits and become sticky if not maintained, affecting engine performance. Regular cleaning is essential.
Suspension Seals:
Fork seal leaks and shock seal failures can occur due to harsh riding conditions and require regular inspection and replacement.
