KTM 200 EXC SIX DAYS Engine 1999-2010 Service Repair Manual

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This manual covers the 200 EXC SIX DAYS, a performance-oriented off-road motorcycle produced between 1999 and 2010. Known for its agile handling and robust off-road capability, the 200 EXC SIX...

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Tipo: Motorcycle

Proveedor:

SKU: 94485

Etiquetas: 1999 200 EXC SIX DAYS 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 SIX DAYS, a performance-oriented off-road motorcycle produced between 1999 and 2010. Known for its agile handling and robust off-road capability, the 200 EXC SIX DAYS represents dedication to enduro riding and racing. The 'Six Days' designation signifies a special edition model, often featuring enhanced components to commemorate involvement in the International Six Days Enduro. This single-cylinder, liquid-cooled, 2-stroke machine offers a compelling power-to-weight ratio, making it a popular choice for demanding trail riding and competitive events. This comprehensive service and repair manual provides detailed technical information for the 200 EXC SIX DAYS motorcycles from 1999 to 2010. It covers a wide array of essential maintenance and repair procedures, including complete engine overhauls, fuel system servicing, ignition system diagnostics, cooling system maintenance, transmission and clutch service, electrical system troubleshooting, and detailed instructions for suspension, brakes, wheels, tires, frame, and bodywork. The manual includes routine maintenance schedules, troubleshooting guides for common issues, and precise specifications and tolerances required for accurate repairs, ensuring optimal performance and longevity of the vehicle.

🏷️ Basic Information

Identification

Make:

Model:

200 EXC SIX DAYS

Engine Type Identifier:

200 EXC SIX DAYS Engine

Product Name:

KTM 200 EXC SIX DAYS Engine 1999-2010 Service Repair Manual PDF

👋 Introduction

Market Position

Segment:

Performance Off-Road Motorcycle (Enduro)

Target Audience:

Owners and technicians of KTM 200 EXC SIX DAYS motorcycles requiring detailed repair and maintenance information.

Competitive Analysis

Value Proposition:

Provides essential, manufacturer-level technical data to ensure proper maintenance and repair, thereby maximizing performance and longevity of the motorcycle.

Key Features

Resource Type:

Comprehensive service and repair manual, essential for any owner undertaking their own maintenance or for independent workshops.

Format Advantage:

Digital PDF format allows for easy access, searching, and printing of specific sections.

📋 Manual Details

Coverage Areas

Applicable Years:

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

Page Count

Estimated Page Count:

Refer to actual manual for precise count (typically 300-500 pages for comprehensive motorcycle service manuals)

Manual Type

Manual Type:

Service Repair Manual

Language

Language:

English

Format

Format:

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Complete engine overhaul, disassembly, assembly, inspection, and repair of all internal components (pistons, rings, cylinders, crankshaft, connecting rods, valves, camshafts, timing components, etc.).

Engine Fuel System:

Carburetor (Mikuni VM series typically), fuel pump, fuel lines, fuel tank maintenance, cleaning, and adjustment procedures.

Engine Ignition System:

CDI ignition, spark plug specifications, troubleshooting, and component testing.

Cooling System:

Radiator, coolant, hoses, water pump maintenance, inspection, and fluid replacement.

Transmission:

Clutch operation, maintenance, adjustment, and disassembly/assembly of the gearbox and related components.

Electrical System:

Wiring diagrams, battery maintenance, charging system (stator, regulator/rectifier), lighting, starter motor, and troubleshooting.

Suspension Front:

Fork maintenance, seal replacement, oil level and type specifications, damping adjustments, and general inspection.

Suspension Rear:

Shock absorber service, linkage maintenance, bearing inspection, and adjustment procedures.

Brakes:

Brake caliper service, pad replacement, fluid flush and bleed, master cylinder inspection, and rotor maintenance.

Wheels And Tires:

Tire pressure recommendations, wheel bearing inspection and replacement, spoke tensioning, and rim maintenance.

Frame And Bodywork:

Frame inspection, body panel removal and installation, seat, handlebars, footpegs, and general chassis maintenance.

Procedures Included

Routine Maintenance:

Oil changes, filter replacements, chain lubrication and adjustment, air filter cleaning/replacement, spark plug checks, and general inspections.

Troubleshooting Guides:

Step-by-step diagnostic procedures for common starting, running, and electrical issues, with symptom-based problem solving.

Rebuild Procedures:

Detailed instructions for complete engine rebuilds, transmission overhauls, and suspension component servicing.

Component Removal Installation:

Instructions for safely removing and reinstalling all major and minor components.

Specifications And Tolerances:

Precise torque values, clearances, fluid levels, and other critical technical data for proper assembly and adjustment.

Technical Depth

Depth Of Coverage:

Comprehensive: Covers everything from basic maintenance to complete engine and chassis overhauls, including detailed diagnostics and component-level repair.

Diagnostic Capability:

Advanced troubleshooting with clear symptom-to-cause analysis and diagnostic flowcharts.

Detail Level:

Highly detailed with clear diagrams, exploded views, and step-by-step instructions, suitable for both amateur and professional mechanics.

📊 Manual Specifications

File Format

File Type:

PDF (Portable Document Format)

Searchability:

Likely text-searchable, allowing for quick location of specific information within the document.

Print Quality

Print Readability:

Designed for clear printing, with high-resolution diagrams and text.

Binding Type

Binding:

N/A (Digital PDF format)

Paper Type

Paper Type:

N/A (Digital PDF format)

⚙️ Engine Specifications

Primary Engine

Engine Displacement:

Approximately 193 cc (specific bore and stroke data would be within the manual)

Engine Configuration:

Single-cylinder, 2-stroke

Cooling System:

Liquid-cooled

Performance

Bore X Stroke:

Typically around 62.5 mm x 65 mm (requires confirmation from manual)

Power Output:

Estimated 30-35 HP (specific figures vary by year and tune)

Torque Output:

Estimated 25-28 Nm (specific figures vary by year and tune)

Fuel System

Carburetor Model:

Likely Mikuni VM series (e.g., VM28 or similar)

Fuel Type:

Unleaded gasoline (95 RON or higher recommended)

Premix Ratio:

Typically 1:40 or 1:50 (2-stroke oil to gasoline, specified by KTM)

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-disc clutch

Optional

Optional Gearbox:

N/A (standard configuration for this model)

Features

Gear Ratios:

Specific gear ratios will be detailed in the manual, critical for performance tuning.

Transmission Oil Type:

Manual will specify appropriate transmission oil (e.g., SAE 80W/90 or similar motorcycle-specific gear oil).

📐 Dimensions

Exterior

Wheelbase:

Varies slightly by year, typically around 1470 mm ± 10 mm (refer to manual for exact specification).

Seat Height:

Varies by year, typically around 960 mm (refer to manual for exact specification).

Weights

Dry Weight:

Approximately 100-110 kg (specific dry weight varies by year and configuration).

Fuel Tank Capacity:

Typically around 8-9 liters (refer to manual for exact specification).

🛡️ Safety Features

Ratings

Safety Standard:

Motorcycle safety standards as per relevant regulatory bodies (e.g., DOT, ADR, CE where applicable).

Active Features

Braking System:

Hydraulic disc brakes front and rear (Brembo calipers common on KTMs of this era).

Suspension Performance:

High-performance adjustable suspension (WP Suspension) crucial for off-road control and safety.

Passive Features

Frame Construction:

Chromoly steel frame provides strength and rigidity.

💡 Technology Features

Infotainment

Display:

Basic digital display showing speed, odometer, trip meter, and warning lights (specific features may vary by year).

Driver Assistance

ABS was not standard or commonly available on off-road models of this era; manual will confirm if an option existed for specific markets/years.

Connectivity

Connectivity Features:

None (no Bluetooth or smartphone integration typical for this model and era).

🔧 Maintenance

Service Intervals

Engine Oil Change:

Typically every 10-15 hours of riding or annually, consult manual for exact hours/miles.

Air Filter Cleaning:

Frequent cleaning recommended, especially in dusty conditions (e.g., every 5-10 hours or as needed).

Spark Plug Check:

Inspect every 20-30 hours of riding, replace as needed.

Chain Lubrication:

Lubricate every 500-800 km or after washing/riding in wet conditions.

Fluid Specifications

Engine Oil Type:

Manual will specify appropriate 2-stroke premix oil and potentially separate gearbox oil (e.g., Motorex or equivalent).

Coolant Type:

Manual will specify recommended coolant (e.g., 50/50 mixture of ethylene glycol and distilled water, or a specific KTM coolant).

Brake Fluid Type:

Manual will specify DOT 4 or DOT 5.1 brake fluid.

Known Issues

Common Wear Items:

Piston and rings, clutch plates, wheel bearings, fork seals, and exhaust packing are common wear items on 2-stroke off-road bikes.

Carburetor Tuning:

Carburetor jetting may require adjustment based on altitude, temperature, and modifications. Manual provides baseline settings.

Exhaust Valve Cleaning:

Power valve system can accumulate carbon deposits and require periodic cleaning for optimal performance.

📚 Vehicle History

Brand Heritage

Manufacturer:

KTM (Kronreif & Trunkenpolz Mattighofen), an Austrian manufacturer renowned for its off-road motorcycles.

Model Evolution

Exc Lineage:

The EXC line represents KTM's commitment to enduro and off-road racing, with the 200 EXC being a popular choice for its lightweight and agile performance.

Six Days Trim:

The 'Six Days' designation typically signifies a special edition model with enhanced features and components, commemorating KTM's participation in the International Six Days Enduro (ISDE).

Production

Production Period:

1999-2010 for the specific model covered by this manual.

🏆 Awards & Recognition

Recognitions

Industry Recognition:

KTM's EXC models are consistently recognized for their off-road performance and competitive spirit in enduro racing and general trail riding.

Ratings

Review Consensus:

Generally praised for agility, power-to-weight ratio, and robust off-road capability.