KTM 200 EXC Engine 1999-2010 Service Repair Manual

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Tipo: Motorcycle

Proveedor:

SKU: 94484

Etiquetas: 1999 200 EXC Engine 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 KTM Misc Motorcycle Motorcycles

Variantes de producto

Descripción

This manual covers the 200 EXC, a highly regarded 2-stroke, single-cylinder motorcycle renowned for its potent power delivery and agile handling. Produced between 1999 and 2010, the 200 EXC embodies the 'Ready to Race' philosophy, offering robust construction and performance tailored for demanding enduro and off-road competition and recreation. Its key features include a high-performance engine, typically equipped with advanced suspension for exceptional adjustability, and a durable chromoly steel trellis frame that contributes to its precise feedback and maneuverability. This model is celebrated for its durability and its lineage rooted in extensive off-road racing success. The purpose of this comprehensive Service and Repair Manual is to provide detailed guidance for the maintenance, repair, and troubleshooting of the 200 EXC. It covers a wide array of systems, including complete engine mechanicals, fuel and ignition systems, transmission and clutch, suspension, brakes, and the electrical system. Within its 300+ pages, owners, mechanics, and technicians will find step-by-step procedures for scheduled maintenance, engine rebuilds, suspension overhauls, carburetor tuning, and electrical diagnostics. This English-language manual ensures efficient access to essential information for keeping the 200 EXC in optimal working condition.

🏷️ Basic Information

Identification

Make:

Model:

200 EXC

Codes

Engine Variant:

2-stroke, single-cylinder

👋 Introduction

Market Position

Segment:

Enduro / Off-Road Competition and Recreation

Competitive Analysis

Competitors:

Yamaha WR250, Honda CR250/CRF250, Suzuki RM250, Kawasaki KX250 (during its 2-stroke era)

Key Features

Engine Type:

High-performance 2-stroke engine known for its potent power delivery and lightweight design.

Suspension:

Typically equipped with high-quality WP suspension components, offering excellent adjustability and performance.

Handling:

Renowned for its agile and precise handling characteristics, a hallmark of KTM off-road motorcycles.

Durability:

Built for demanding off-road use, with robust components designed for longevity under harsh conditions.

📋 Manual Details

Coverage Areas

Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010

Page Count

Estimated Pages:

Manual Type

Type:

Service and Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete disassembly, inspection, and reassembly of engine components (cylinder, piston, crankshaft, connecting rod, bearings, seals, gaskets, etc.)

Fuel System:

Carburetor service and tuning (e.g., Keihin PWK), fuel lines, fuel tank, petcock

Ignition System:

CDI unit, ignition coil, spark plug, timing adjustment

Cooling System:

Radiator, cooling fan, water pump, coolant flow, thermostat

Transmission And Clutch:

Gearbox, shift drum, shift forks, clutch assembly (plates, springs, basket), hydraulic clutch system

Exhaust System:

Exhaust pipe, silencer maintenance, power valve operation and adjustment

Suspension:

Front fork (WP USD) service, seal replacement, oil levels, rear shock absorber service

Brakes:

Hydraulic brake systems (front and rear), caliper service, master cylinder, brake fluid replacement, pad replacement, bleeding procedures

Electrical System:

Wiring diagrams, lighting, charging system (stator, regulator/rectifier), battery maintenance, starter system (if applicable to specific sub-models)

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm bearing service

Wheels And Tires:

Spoke tensioning, wheel bearing replacement, tire fitting and removal

Procedures Included

Scheduled Maintenance:

Detailed procedures for routine checks, oil changes, filter replacements, spark plug replacement, chain adjustment, and general inspections at specified intervals.

Troubleshooting:

Diagnostic charts and procedures for identifying and resolving common mechanical and electrical issues.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly, cleaning, inspection, part replacement (e.g., piston kits, crankshafts), and reassembly with torque specifications.

Suspension Overhaul:

Instructions for fork seal replacement, bushing replacement, and rear shock absorber rebuild.

Carburetor Tuning:

Guidance on jetting, idle speed adjustment, and general carburetor maintenance for optimal performance.

Clutch Adjustment:

Procedures for adjusting clutch cable or hydraulic system for proper engagement and disengagement.

Electrical Diagnosis:

Fault finding for ignition, charging, and lighting systems using wiring diagrams.

Brake System Maintenance:

Bleeding, pad replacement, caliper service, and master cylinder maintenance.

Technical Depth

Depth:

Comprehensive: Covers everything from basic owner maintenance checks to complete engine and chassis overhauls, including detailed specifications and troubleshooting guides.

📊 Manual Specifications

File Format

File Type:

Digital PDF

Searchability:

Text-searchable PDF for quick access to information

Print Quality

Resolution:

High-resolution scans for clear text and diagrams

Binding Type

Binding:

N/A (Digital Format)

Paper Type

Paper Type:

N/A (Digital Format)

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, single-cylinder, liquid-cooled, reed valve induction

Displacement:

193 cc (approximately)

Bore X Stroke:

62.5 mm x 65 mm (typical for this era)

Compression Ratio:

Varies by year, typically around 8.0:1 to 8.5:1

Cylinder Head:

Single spark plug, liquid-cooled cylinder head

Lubrication:

Premix fuel-oil or automatic oil injection (depending on specific sub-model year)

Performance

Horsepower Estimate:

Approximately 30-35 HP (at crankshaft, depending on tuning and year)

Torque Estimate:

Approximately 20-23 lb-ft (at crankshaft, depending on tuning and year)

Fuel System

Carburetor Type:

Keihin PWK 36 (common for this model)

Fuel Type:

Unleaded gasoline, 95-98 octane recommended (RON)

Ignition System

Ignition Type:

Digital CDI with variable ignition timing

Engine Internals

Piston Type:

Single-ring, lightweight piston

Connecting Rod:

High-strength, forged connecting rod

🔧 Transmission

Standard

Type:

6-speed constant mesh gearbox

Clutch Type:

Wet, multi-plate clutch (hydraulically operated)

Features

Gear Ratios:

Specific gear ratios are detailed within the manual.

Final Drive:

Chain drive (e.g., 520 pitch)

📐 Dimensions

Exterior

Wheelbase:

Approximately 1450 mm (57.1 inches)

Seat Height:

Approximately 960 mm (37.8 inches)

Weights

Dry Weight:

Approximately 94 kg (207 lbs)

Fuel Capacity:

Approximately 7.5 - 9 liters (1.9 - 2.4 US gallons), depending on model year and tank size.

🛡️ Safety Features

Ratings

Crash Safety:

Not applicable for off-road motorcycles in the same way as passenger vehicles. Focus is on rider protection via chassis integrity and component durability.

Active Features

Braking System:

Powerful hydraulic disc brakes front and rear, typically Brembo components.

Passive Features

Chassis Construction:

High-strength chromoly steel trellis frame for optimal rigidity and rider feedback.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Designed for performance and off-road functionality, no infotainment system).

Driver Assistance

Rider Aids:

Minimal; focused on rider control. May include features like a kill switch, sometimes a basic hour meter.

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Oil Change Engine:

Every 10-15 hours of riding or annually. (Refer to manual for precise intervals)

Air Filter Cleaning:

After every few rides, depending on riding conditions.

Spark Plug Replacement:

Every 20-30 hours of riding.

Piston Ring Replacement:

Every 50-75 hours of riding (service life depends on riding style and maintenance).

Full Engine Rebuild:

Typically recommended every 100-150 hours of riding for optimal performance and reliability.

Fluid Specifications

Engine Oil Type:

2-stroke premix oil, specific ratio (e.g., 1:40 or 1:50) as per KTM recommendations.

Transmission Oil Type:

Specific gearbox oil (e.g., Motorex Gear Oil 80W or equivalent).

Clutch Fluid Type:

DOT 4 brake fluid for hydraulic clutch systems.

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors.

Known Issues

Power Valve Sticking:

Common issue in 2-strokes due to carbon buildup; requires regular cleaning and maintenance. Manual covers cleaning and adjustment.

Clutch Lever Adjustment:

Hydraulic clutch systems may require occasional bleeding to maintain proper feel. Manual provides bleeding procedures.

Suspension Seals:

Fork seals can wear over time, especially with aggressive riding. Manual details seal replacement.

📚 Vehicle History

Brand Heritage

Ktm Legacy:

KTM, known as 'Ready to Race,' has a long and successful history in off-road racing, particularly in enduro and motocross.

Model Evolution

Exc Lineage:

The EXC line represents KTM's commitment to producing competitive and durable off-road motorcycles, evolving from their racing success.

Production

Manufacturing Location:

Austria (primarily KTM's main manufacturing facility)

🏆 Awards & Recognition

Recognitions

Off Road Popularity:

KTM EXC models consistently receive accolades and are highly regarded by off-road enthusiasts for their performance, reliability, and racing pedigree.

Ratings

Magazine Reviews:

Frequently reviewed positively in off-road motorcycling publications for their powerful engines and excellent chassis dynamics.

Certifications

Emissions:

Compliance with relevant emissions standards for off-road motorcycles of the respective production years.