KTM 200 EXC 1999-2003 Factory Service Repair Manual

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Taper: Motorcycle

Distributeur:

UGS: 78461

Mots clés: 1999 200 EXC 2000 2001 2002 2003 KTM Misc Motorcycle Motorcycles

Variantes de produits

Description

The KTM 200 EXC, produced between 1999 and 2003, is a highly capable off-road motorcycle renowned for its lightweight design, agile handling, and potent two-stroke performance. Engineered for demanding enduro and trail riding conditions, this model embodies KTM's strong heritage in off-road competition. Its robust 192.7 cc liquid-cooled engine, paired with a 6-speed transmission and hydraulically operated clutch, delivers exhilarating power and precise control. The advanced chassis, featuring a chromoly steel trellis frame and high-quality suspension components, ensures durability and responsiveness on challenging terrain, making it a favored choice for riders seeking a competitive edge. This comprehensive Factory Service Repair Manual provides in-depth information for the maintenance, repair, and servicing of the KTM 200 EXC models from 1999 to 2003. It covers all essential systems, including the engine, transmission, chassis, electrical system, suspension, brakes, and fuel system. The manual offers detailed procedures for routine maintenance, major repairs, engine overhauls, and component disassembly and reassembly, along with systematic troubleshooting guides and diagnostic charts. With factory-level detail and precise torque specifications, this English-language manual is an indispensable resource for owners, mechanics, and technicians aiming to keep their 200 EXC performing at its peak.

🏷️ Basic Information

Identification

Make:

Model:

200 EXC

Model Code:

KTM 200 EXC

Generation

Model Years Covered:

1999, 2000, 2001, 2002, 2003

👋 Introduction

Market Position

Segment:

Off-road, Enduro

Competitive Analysis

Competitors 1999-2003:

Husqvarna WR250, Yamaha YZ250 WR, Suzuki RMX250, Honda CR250R E

Key Features

Bike Focus:

Lightweight, agile, powerful two-stroke performance for off-road competition and trail riding.

📋 Manual Details

Coverage Areas

Systems Covered:

Engine, Transmission, Chassis, Electrical System, Suspension, Brakes, Fuel System, Cooling System, Exhaust System, Bodywork, Troubleshooting, Maintenance, Specifications

Page Count

Page Count:

Hundreds of pages (specific count not provided, but described as comprehensive)

Manual Type

Manual Type:

Factory Service Repair Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Overhaul:

Complete engine disassembly, inspection, repair, and reassembly procedures for the 200cc two-stroke engine.

Transmission Service:

Detailed instructions for gearbox maintenance, clutch service, and troubleshooting transmission issues.

Chassis And Suspension:

Procedures for fork and shock absorber service, linkage maintenance, frame inspection, and wheel bearing replacement.

Electrical Diagnostics:

Wiring diagrams, troubleshooting guides for ignition, lighting, and charging systems, as well as component testing.

Brake System Maintenance:

Guidance on brake pad replacement, caliper service, master cylinder maintenance, and bleeding procedures.

Fuel And Carburetion:

Detailed information on carburetor adjustment, cleaning, jetting, and fuel system component inspection.

Frame And Bodywork:

Repair procedures for plastic body panels, seat, fuel tank, and frame components.

Procedures Included

Routine Maintenance:

Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, and spark plug service.

Troubleshooting Guides:

Systematic approaches to diagnosing and resolving common operational problems and failures.

Major Repairs:

Instructions for significant component overhauls and replacements, including engine rebuilds.

Component Disassembly Reassembly:

Step-by-step guides for taking apart and putting back together all major motorcycle systems.

Engine Tuning:

Basic tuning advice, carburetor jetting, and exhaust modification considerations.

Wheel And Tire Service:

Information on tire changes, wheel balancing, and spoke tensioning.

Diagnostic Charts:

Flowcharts and tables to systematically diagnose common problems.

Technical Depth

Depth Of Information:

Comprehensive factory-level detail suitable for professional technicians and experienced DIY mechanics.

Torque Specifications:

Precise torque values for all critical fasteners.

Clearances And Tolerances:

Detailed specifications for engine component clearances, bearing tolerances, etc.

Wiring Diagrams:

Full electrical system schematics for troubleshooting and repairs.

📊 Manual Specifications

File Format

File Format:

Print Quality

Print Quality:

High-resolution for clear reproduction of text and diagrams.

Binding Type

Binding Type:

N/A (Digital Download)

Paper Type

Paper Type:

N/A (Digital Download)

Searchability

Searchable Text:

Likely features searchable text within the PDF for quick information retrieval.

⚙️ Engine Specifications

Primary Engine

Engine Type:

2-stroke, Single Cylinder

Displacement:

192.7 cc (11.77 cu in)

Bore X Stroke:

62.5 mm x 62.4 mm (2.46 in x 2.46 in)

Cooling System:

Liquid-cooled

Carburetor:

Keihin PWK 39

Performance

Horsepower Approx:

~40 hp @ 8,500 rpm (Estimate, official figures vary)

Torque Approx:

~35 Nm @ 7,500 rpm (Estimate, official figures vary)

Fuel System

Fuel Type:

Unleaded gasoline with 2-stroke oil pre-mix

Fuel Ratio:

1:40 or 1:50 (recommended by KTM)

Ignition System

Ignition Type:

Digital CDI ignition system

🔧 Transmission

Standard

Transmission Type:

6-speed constant mesh

Clutch Type:

Wet multi-disc clutch, hydraulically operated

Features

Gear Ratios:

Specific ratios available in manual, typically focused on off-road performance.

Transmission Oil Spec:

KTM recommends specific gearbox oil, often a SAE 80W/90 API GL-4.

📐 Dimensions

Exterior

Wheelbase:

Approx. 1470 mm (57.9 in)

Ground Clearance:

Approx. 350 mm (13.8 in)

Weights

Dry Weight:

Approx. 104 kg (229 lbs)

Fuel Tank Capacity:

Approx. 9 liters (2.4 US gal)

🛡️ Safety Features

Ratings

Safety Certification:

Not applicable for off-road competition motorcycles in the same way as street vehicles.

Active Features

Braking System:

Hydraulic disc brakes front and rear. Brembo components often used.

Passive Features

Frame Construction:

Chromoly steel trellis frame for rigidity and impact resistance.

💡 Technology Features

Infotainment

Infotainment Features:

N/A (Basic off-road competition focus, no electronic infotainment systems).

Driver Assistance

Assistance Systems:

N/A (Mechanical systems only).

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

Refer to manual; typically every 15-25 hours of riding for gearbox oil.

Top End Rebuild Interval:

Highly variable based on use; can range from 50-100+ hours for piston/rings, and 100-200+ hours for a full engine rebuild.

Fluid Specifications

Engine Oil Type:

Premix 2-stroke oil, specific grade and brand recommendations in manual.

Coolant Type:

Ethylene glycol-based antifreeze mixture.

Brake Fluid Type:

DOT 4 brake fluid.

Fork Oil Type:

Specific fork oil weight and level specified in the manual (e.g., WP suspension fluid).

Known Issues

Common Wear Items:

Piston rings, clutch plates, wheel bearings, swingarm pivot bearings, steering head bearings, fork seals, exhaust packing.

Potential Problems:

Carburetor jetting sensitivity to altitude and temperature, reed valve wear, kickstart mechanism wear.

📚 Vehicle History

Brand Heritage

Ktm Offroad Legacy:

KTM has a long-standing reputation for producing highly competitive off-road motorcycles, particularly in motocross and enduro racing.

Model Evolution

200 Exc Lineage:

The 200 EXC was part of KTM's successful small-displacement off-road lineup, offering a potent blend of power and manageability.

Production

Manufacturing Location:

Austria (primarily)

🏆 Awards & Recognition

Recognitions

Offroad Magazine Reviews:

KTM 200 EXC models from this era generally received positive reviews for their performance and handling in specialized off-road publications.