KTM 200 EXC 1999-2010 Workshop Service Manual for Repair

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Tipo: Motorcycle

Proveedor:

SKU: 80972

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

Variantes de producto

Descripción

The 200 EXC, produced from 1999 through 2010, is a celebrated enduro motorcycle renowned for its aggressive two-stroke power delivery and lightweight, agile design. Built upon a robust chromoly steel frame and equipped with high-performance suspension components, this model is engineered for demanding off-road conditions, excelling in trails, hard enduro, and motocross riding. The strong off-road racing heritage is evident in the 200 EXC's platform, which consistently refined its engine performance, suspension tuning, and component durability throughout its production years, making it a favored choice among off-road enthusiasts and competitive riders. This comprehensive workshop service and repair manual, presented in English, covers the 200 EXC models from 1999 to 2010. Within its 280 pages, you will find detailed instructions for engine overhaul, transmission maintenance, fuel and ignition system tuning, cooling system service, suspension adjustments, brake system repair, and electrical system troubleshooting. The manual also includes essential preventive maintenance schedules, systematic diagnostic guides for common issues, and in-depth procedures for component rebuilds, all supported by technical data charts and specifications. This resource is designed to assist owners, mechanics, and technicians in effectively maintaining and repairing the vehicle to ensure optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Model:

200 EXC

Production Years Covered:

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

Model Code Range:

Specific chassis codes may vary within these years; manual covers all 200 EXC variants.

👋 Introduction

Market Position

Vehicle Segment:

Enduro Motorcycle

Target Audience:

Off-road enthusiasts, trail riders, and competitive enduro riders seeking performance and durability.

Competitive Analysis

Competitors:

Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (two-stroke era).

Key Features

Engine Type:

Aggressive two-stroke power delivery, lightweight design.

Chassis:

Strong chromoly steel frame, WP suspension components.

Off Road Capability:

Designed for demanding off-road conditions, including trails, hard enduro, and motocross.

📋 Manual Details

Coverage Areas

Manual Type:

Workshop Service Manual / Repair Manual

Page Count:

Language:

English

Format:

PDF Download

Delivery Method:

Instant Digital Download

📖 Manual Coverage

Systems Covered

Engine:

Complete engine overhaul, disassembly, assembly, tuning, and diagnostics for the 200cc two-stroke engine.

Transmission:

Clutch, gearbox (including gear inspection, replacement, and lubrication), and final drive maintenance.

Fuel System:

Carburetor (Mikuni VM28 or similar), fuel tank, fuel lines, and petcock maintenance and tuning.

Ignition System:

CDI ignition, spark plug specifications, timing adjustments, and troubleshooting.

Cooling System:

Liquid cooling system, radiator, hoses, water pump maintenance, and coolant specifications.

Exhaust System:

Expansion chamber, silencer inspection, and repacking procedures.

Suspension:

Front forks (WP USD), rear shock absorber (WP), suspension adjustments, oil changes, seal replacement, and general service.

Brakes:

Hydraulic disc brakes (front and rear), caliper service, pad replacement, fluid bleeding, master cylinder maintenance, and rotor specifications.

Electrical System:

Wiring diagrams, battery maintenance, lighting system, switchgear, and basic electrical troubleshooting.

Frame And Bodywork:

Frame inspection, handlebar and control adjustments, seat removal, body panel repair and fitting.

Procedures Included

Preventive Maintenance:

Detailed schedules for oil changes, filter replacements, chain adjustment, and general inspections.

Troubleshooting:

Systematic guides for diagnosing common problems with the engine, transmission, electrical system, and chassis.

Repair Procedures:

Step-by-step instructions for component disassembly, repair, reassembly, and adjustment.

Rebuilds:

Comprehensive guides for engine and transmission rebuilds, including torque specifications and clearances.

Technical Data Charts:

Inclusion of specification tables, torque values, fluid capacities, and electrical resistance values.

Technical Depth

Depth:

Advanced diagnostics and detailed repair procedures suitable for professional mechanics and experienced DIY enthusiasts.

Diagnostic Tools:

While specific diagnostic tool mentions might be limited, the manual provides the fundamental knowledge for diagnosing mechanical and electrical issues.

📊 Manual Specifications

File Format

Format:

Searchable:

Likely searchable text within the PDF for quick information retrieval.

Printable:

High-quality PDF format suitable for printing individual sections or the entire manual.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-stroke, liquid-cooled, single-cylinder

Displacement:

Approximately 193 cc (bore x stroke typically around 62.5 mm x 64 mm)

Bore X Stroke:

Refer to manual for exact specifications, typically 62.5 x 64 mm

Compression Ratio:

Varies by year and specific tuning, typically around 8.5:1 to 9.5:1 for stock configuration.

Performance

Horsepower:

Estimated 35-40 HP (stock configuration), power output can vary significantly with tuning and modifications.

Torque:

Refer to manual for exact specifications; known for strong low-to-mid range power.

Fuel System

Carburetor Type:

Typically Mikuni VM28 or similar, with specific jetting and tuning recommendations in the manual.

Fuel Type:

Leaded or unleaded gasoline with appropriate octane rating, premixed with two-stroke oil.

Oil Mixture Ratio:

Refer to manual, typically 30:1 or 40:1, depending on oil type and riding conditions.

Lubrication

Engine Oil Type:

Specific two-stroke engine oil required; refer to manual for recommended grades and specifications.

🔧 Transmission

Standard

Type:

6-speed constant mesh

Clutch:

Hydraulic actuated, multi-plate wet clutch.

Features

Gear Ratios:

Specific gear ratios provided within the manual for detailed analysis and potential modification.

Final Drive:

Chain drive; manual includes chain inspection, adjustment, and sprocket replacement procedures.

📐 Dimensions

Exterior

Frame Type:

Chromoly steel trellis frame

Suspension Travel Front:

Approximately 295-300 mm (WP USD forks)

Suspension Travel Rear:

Approximately 300-320 mm (WP Monoshock)

Weights

Dry Weight:

Approximately 95-100 kg (varies slightly by year)

Fuel Tank Capacity:

Approximately 9-12 liters (varies by year and specific model variant)

🛡️ Safety Features

Ratings

Safety Features:

N/A for off-road specific motorcycles in terms of formal crash ratings; focus is on rider control and vehicle stability.

Active Features

Brakes:

Powerful hydraulic disc brakes front and rear for effective stopping power.

Suspension:

High-quality WP suspension provides optimal grip and control over varied terrain.

Passive Features

Frame Strength:

Robust chromoly steel frame offers excellent rigidity and impact resistance.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Purely functional off-road motorcycle)

Driver Assistance

Electronic Aids:

N/A (Mechanical focus, no electronic rider aids)

Connectivity

Connectivity Features:

🔧 Maintenance

Service Intervals

Engine Oil Change:

Refer to manual, typically every 15-20 hours of riding for 2-stroke premix.

Air Filter Cleaning:

Regularly, often every few rides or after dusty conditions; detailed cleaning and oiling procedures in manual.

Spark Plug Replacement:

As per manual recommendations, typically every 20-40 hours of riding depending on plug type and condition.

Suspension Service:

Fork oil and seal replacement typically every 40-60 hours; rear shock service as per manual.

Fluid Specifications

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors; specific KTM recommendations should be followed.

Brake Fluid Type:

DOT 4 or DOT 5.1 hydraulic brake fluid; refer to manual for precise specification.

Transmission Oil Type:

Dedicated 2-stroke engine oil for premix (not gearbox oil); manual specifies suitable types.

Known Issues

Power Valve Sticking:

Common in 2-stroke engines, requires periodic cleaning and lubrication. Manual covers disassembly and service.

Carburetor Tuning:

Can be sensitive to altitude and temperature changes; manual provides comprehensive tuning guidance.

Suspension Seals:

Wear on fork seals can lead to leaks; manual details seal replacement procedures.

Clutch Wear:

Clutch plates can wear over time, requiring adjustment or replacement. Manual provides clutch service details.

📚 Vehicle History

Brand Heritage

Brand Focus:

KTM is renowned for its off-road racing heritage, consistently producing high-performance dirt bikes.

Model Evolution

Platform:

The 200 EXC represents a lineage of KTM's successful EXC enduro models, known for their aggressive power and nimble handling.

Key Changes:

Minor updates and refinements throughout the 1999-2010 period, focusing on suspension tuning, engine performance, and component durability.

Production

Manufacturing Location:

Austria (KTM's primary manufacturing hub)

🏆 Awards & Recognition

Recognitions

Brand Recognition:

KTM consistently receives accolades for its performance-oriented off-road motorcycles.

Ratings

Off Road Capability Ratings:

Praised by off-road publications for its agility, power, and suspension performance during its production run.

Certifications

Manufacturing Standards:

Built to KTM's stringent European manufacturing standards.