🏷️ Basic Information

Make:

KTM

Model:

200 EXC

Product Type:

Factory Service Repair Manual

👋 Introduction

Vehicle Segment:

Off-road competition motorcycle (Enduro/Cross-Country)

Target Audience:

Enthusiast riders, amateur racers, and professional mechanics working on KTM 200 EXC models.

Competitors:

Other 200cc-300cc class off-road motorcycles from brands like Husqvarna, Beta, Sherco, and Yamaha.

Manual Utility:

Provides essential information for DIY maintenance, repairs, and performance tuning.

Manual Advantage:

Factory-level accuracy and detail, ensuring correct procedures and specifications are followed.

📋 Manual Details

Manual Type:

Service Repair Manual

Language:

English

Format:

PDF Download

📖 Manual Coverage

Engine:

Comprehensive engine overhaul, diagnosis, and tuning for the 200 EXC engine.

Transmission:

Detailed procedures for gearbox disassembly, inspection, assembly, and adjustment.

Chassis:

Suspension (front and rear forks, shock absorber), frame, swingarm, and steering head bearing service.

Electrical System:

Wiring diagrams, component testing, troubleshooting for ignition, lighting, charging, and starter systems.

Fuel System:

Carburetor (if applicable) tuning, cleaning, and repair; fuel tank and lines.

Brakes:

Front and rear brake system overhaul, including caliper, master cylinder, and hydraulic line service.

Cooling System:

Radiator, water pump, thermostat, and coolant system maintenance.

Exhaust System:

Removal, installation, and inspection of exhaust components.

Wheels And Tires:

Wheel bearing service, spoke tensioning, tire changing, and balancing.

Maintenance:

Scheduled maintenance tasks, fluid changes, filter replacements, and general inspections.

Disassembly:

Step-by-step instructions for removing and separating all major components.

Assembly:

Detailed guidance for reassembling components with correct torque specifications.

Repair:

Instructions for repairing or replacing worn or damaged parts.

Troubleshooting:

Diagnostic flowcharts and common problem identification for various systems.

Adjustments:

Calibration and adjustment procedures for engine, brakes, and suspension.

Depth:

Comprehensive, covering basic maintenance to full engine rebuilds and advanced diagnostics.

📊 Manual Specifications

File Type:

PDF

Searchable Text:

Yes (typically, dependent on original scan quality)

Printable:

Yes

Quality:

High resolution for clear diagrams and text

Binding:

N/A (Digital PDF Download)

Paper:

N/A (Digital PDF Download)

⚙️ Engine Specifications

Engine Type:

Single-cylinder, 2-stroke, liquid-cooled

Displacement:

193 cc (Approximate, may vary slightly by year/spec)

Bore X Stroke:

Refer to manual for specific year's exact dimensions

Compression Ratio:

Refer to manual for specific year's exact ratio

Ignition:

Digital CDI ignition

Starting System:

Electric starter

Horsepower:

Approximately 35-40 HP (varies by year and tuning)

Torque:

Refer to manual for specific year's torque figures

Carburetor:

Keihin PWK 38 (common, but verify specific model year)

Fuel Type:

Unleaded gasoline (minimum 95 octane recommended for optimal performance)

Fuel Mixture:

Pre-mix: Typically 1:40 or 1:50 ratio of specific 2-stroke oil to gasoline (refer to manual for exact ratio and oil type)

Coolant Type:

Ethylene glycol-based coolant with corrosion inhibitors (e.g., Motorex Coolant M3.0 or equivalent)

2-Stroke Oil:

High-quality synthetic 2-stroke engine oil specifically for off-road/competition use (e.g., Motorex, Liqui Moly, Bel-Ray)

🔧 Transmission

Gearbox:

6-speed manual claw-shifted transmission

Clutch:

Hydraulically operated clutch (Magura)

Final Drive:

Chain drive (e.g., 13T front sprocket, 48T rear sprocket common, check manual for specific gearing)

Ratios:

Refer to manual for specific year's gear ratios

Oil Type:

Refer to manual for specific gearbox oil specification (typically SAE 75W/80 or SAE 80W gear oil)

📐 Dimensions

Wheelbase:

Refer to manual for specific year's wheelbase

Seat Height:

Refer to manual for specific year's seat height

Dry Weight:

Approximately 94-96 kg (207-212 lbs) (varies by year and equipment)

Fuel Tank Capacity:

Approximately 7.2 liters (1.9 US gal) (check manual for specific capacity)

Front Wheel Size:

21 x 1.60 (typical for off-road use)

Rear Wheel Size:

18 x 1.85 (typical for off-road use)

Front Tire Size:

80/100-21 (typical, e.g., Michelin Enduro Competition or Dunlop Geomax) (check manual for approved sizes)

Rear Tire Size:

100/90-18 or 110/100-18 (typical, e.g., Michelin Enduro Competition or Dunlop Geomax) (check manual for approved sizes)

Bolt Pattern:

N/A (spoked wheels with captive axle nuts)

🛡️ Safety Features

Crash Safety:

N/A (Off-road motorcycles are not typically crash-tested to automotive standards)

Brakes:

Hydraulic disc brakes front and rear (Brembo calipers common).

Suspension:

WP Suspension components (e.g., WP XPLOR forks, WP PDS rear shock absorber) designed for off-road performance and control.

Ergonomics:

Designed for rider control and maneuverability in demanding off-road conditions.

💡 Technology Features

Infotainment System:

N/A (This is a competition off-road motorcycle; no infotainment system is present.)

Electronic Aids:

Typically no electronic rider aids beyond basic engine management (e.g., CDI unit). Advanced models might feature traction control or engine maps, but the 200 EXC is generally a more analog machine.

Connectivity Features:

N/A (No connectivity features present on this model.)

Headlight:

Halogen or LED headlight, depending on the specific model year.

Taillight:

LED taillight for improved visibility.

🔧 Maintenance

Oil Change Interval:

Refer to manual: typically every 10-15 hours of riding for gearbox oil, and gearbox oil changes when serviced.

Air Filter Cleaning:

Refer to manual: recommended after every few rides or as conditions dictate, especially in dusty environments.

Spark Plug Replacement:

Refer to manual: typically every 50-75 hours of riding, or as needed based on performance.

Piston Ring Replacement:

Refer to manual: typically recommended between 50-100 hours of hard riding for optimal performance and compression.

Top End Rebuild:

Refer to manual: often recommended between 100-200 hours, depending on riding style and maintenance.

Engine Oil:

2-stroke engine oil (refer to manual for specific viscosity and API/JASO rating, e.g., Motorex Power Synt M)

Gearbox Oil:

Gear oil (refer to manual for specific viscosity and type, e.g., Motorex Gear Oil 10W/40 or 75W/80)

Coolant:

Ethylene glycol-based coolant (e.g., Motorex Coolant M3.0)

Brake Fluid:

DOT 4 hydraulic brake fluid (e.g., Motul DOT 4 RBF)

Common Wear Items:

Clutch plates, piston rings, exhaust packing, chain and sprockets, wheel bearings, linkage bearings, fork seals, and air filter are common wear items in high-performance off-road motorcycles.

Carburetor Tuning:

Carburetor jetting may require adjustment based on altitude, temperature, and modifications for optimal performance and fuel efficiency.

📚 Vehicle History

Heritage:

KTM is renowned for its off-road racing heritage and 'Ready to Race' philosophy, with a strong presence in motocross, enduro, and rally racing.

Evolution:

The 200 EXC has evolved from earlier KTM 125/200cc off-road models, consistently refined for performance, reliability, and rider feedback in the enduro segment. Specific model years introduce updates to suspension, engine tuning, ergonomics, and aesthetics.

Manufacturing Origin:

Austria (KTM's primary manufacturing base)

Production Years:

The 200 EXC model has been produced for various model years, with updates occurring periodically. The manual covers a specific range of these years, indicated by its title or description.