Production Years Covered:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Chassis Codes:
KTM EXC 200 (specific chassis codes per year may vary, consult manual for precise VIN decoding)
Segment:
Enduro / Off-Road Motorcycle
Target User:
Enthusiast riders, off-road competitors, adventure riders seeking reliable performance and self-sufficiency.
Key Competitors:
Yamaha WR200, Suzuki DR-Z250, Honda CR250R (though the EXC 200 is a 2-stroke, it competes in displacement class).
Vehicle Focus:
Lightweight, agile, potent 2-stroke engine optimized for technical off-road riding, trail riding, and competitive enduro use.
Manual Value Proposition:
Essential resource for maintaining peak performance, diagnosing issues, and performing repairs on the KTM 200 EXC, maximizing its lifespan and usability.
Engine:
Full engine overhaul, top-end rebuild (cylinder, piston, head), bottom-end service (crankshaft, bearings, seals), valve adjustment, cooling system, lubrication system, exhaust system.
Transmission:
Gearbox disassembly and reassembly, clutch service, shift mechanism, gear oil specifications and change intervals.
Chassis:
Frame inspection and repair, suspension (forks, shock absorber - including seals, oil, and valving), steering system, swingarm, linkages.
Brakes:
Hydraulic brake system service (front and rear), caliper overhaul, master cylinder maintenance, bleeding procedures, pad replacement, rotor inspection.
Electrical:
Wiring diagrams, ignition system troubleshooting, lighting circuits, battery maintenance, starter motor, charging system (stator, regulator/rectifier).
Fuel System:
Carburetor service and tuning (likely Keihin PWK type), fuel tank, fuel lines, petcock.
Cooling System:
Radiator service, coolant specifications, water pump, thermostat operation.
Bodywork:
Panel removal and installation, seat, fenders, fairings, graphics.
Preventative Maintenance:
Scheduled maintenance tasks, lubrication points, filter changes (air, oil), chain and sprockets care, spark plug replacement.
Troubleshooting:
Diagnostic flowcharts, common problems and their solutions, symptom-based troubleshooting guides.
Repair:
Step-by-step repair instructions for all major mechanical and electrical components, including torque specifications and special tool requirements.
Rebuilds:
Detailed instructions for complete engine, transmission, and suspension component rebuilds.
Adjustments:
Carburetor jetting, idle speed, clutch cable, brake levers, suspension sag.
Depth:
Full factory-level technical detail, suitable for professional mechanics and experienced DIY enthusiasts. Covers everything from basic fluid changes to complete engine teardowns and rebuilds.
Type:
2-Stroke Single Cylinder
Displacement:
193 cc (approx.)
Bore X Stroke:
Specific to KTM 200 EXC models of this era (refer to manual for exact figures, e.g., 62.5 mm x 65 mm is common for similar KTM models).
Cooling System:
Liquid-cooled
Compression Ratio:
Specific to model year, typically around 8.4:1 to 8.6:1 for 2-strokes of this era.
Horsepower:
Approximately 35-40 HP (actual figures vary by model year and tuning).
Torque:
Approximately 25-28 Nm (actual figures vary).
Carburetor:
Likely Keihin PWK 38mm or similar, with specific jetting provided in the manual.
Fuel Type:
Unleaded gasoline (minimum 91 RON/87 AKI), pre-mix with 2-stroke oil.
Cylinder Head Design:
Removable cylinder head for piston access and combustion chamber service.
Power Valve System:
Features an exhaust power valve system for improved low-end torque and top-end power delivery.
Type:
6-speed manual transmission
Clutch Type:
Hydraulically operated wet multi-plate clutch
Gear Ratios:
Specific gear ratios for each of the 6 speeds will be detailed in the manual. Critical for off-road performance tuning.
Gearbox Oil Type:
Specific KTM recommended or API GL-4/GL-5 gear oil (e.g., Motorex Gear Oil).
Clutch Fluid Type:
DOT 4 hydraulic brake fluid.
Oil Change Engine:
Recommended every 10-15 hours of riding or annually, depending on usage severity. (Specific interval in manual).
Air Filter Cleaning:
Recommended after every few rides or when visibly dirty, especially in dusty conditions. (Detailed procedure in manual).
Spark Plug Replacement:
Typically every 20-30 hours of riding or as needed based on inspection. (Specific part number and gap in manual).
Top End Rebuild:
Recommended every 50-100 hours of intensive use, depending on riding style and maintenance. (Manual details tolerances and procedures).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0).
Fork Oil Type:
Specific weight (e.g., 5W or 7.5W) and volume for front forks (e.g., WP PDS forks). Manual specifies exact type and quantity.
Rear Shock Oil:
Specific oil for WP PDS rear shock absorber. Manual will provide type and quantity.
Common Wear Items:
Piston rings, clutch plates, fork seals, swingarm bearings, steering head bearings, exhaust packing.
2 Stroke Specific:
Regular decarbonization of exhaust port and power valve recommended to maintain performance.
Chain Maintenance:
Regular cleaning, lubrication, and tension adjustment are critical for drivetrain longevity and performance.
Ktm Legacy:
KTM, an Austrian manufacturer, has a deep-rooted history in off-road motorsport, renowned for its 'Ready to Race' philosophy and success in enduro, motocross, and rally racing.
Exc Lineage:
The EXC line has consistently been KTM's flagship off-road enduro offering, evolving with engine technology, chassis design, and suspension advancements. The 200 EXC represents a highly successful iteration offering a potent and lightweight package.
Manufacturing Location:
Austria (primarily, as per KTM's manufacturing base).
