Segment:
Off-road, Enduro motorcycle.
Competitors:
Competed against models from Yamaha (YZ250, WR250), Honda (CR250, XR250), Suzuki (RM250, DR-Z250), and Kawasaki (KX250, KLX250) in its era.
Brand Reputation:
KTM is renowned for its high-performance, off-road focused motorcycles with strong European engineering.
Model Attributes:
The 200 EXC is characterized by its lightweight chassis, potent two-stroke engine, and agile handling, making it a formidable competitor in enduro and trail riding.
Engine Mechanical:
Top-end rebuild (cylinder, piston, rings, head), bottom-end rebuild (crankshaft, connecting rod, bearings), valve clearance adjustment, timing chain inspection and replacement, cooling system service.
Fuel System:
Carburetor disassembly, cleaning, and adjustment (likely Keihin or Mikuni), fuel filter replacement, fuel line inspection.
Ignition System:
Spark plug replacement and gap setting, CDI unit testing, ignition coil inspection.
Exhaust System:
Exhaust pipe and muffler inspection, gasket replacement.
Transmission And Drivetrain:
Clutch operation and adjustment, gearbox disassembly and reassembly, gear inspection, chain and sprocket wear assessment, lubrication.
Suspension Front:
Fork oil change, seal replacement, internal component inspection and service, spring preload adjustment (if applicable).
Suspension Rear:
Shock absorber service and adjustment, linkage bearing inspection and lubrication, swingarm bearing service.
Brakes Front:
Brake caliper overhaul, brake pad replacement, brake fluid flush and bleeding, disc inspection.
Brakes Rear:
Brake caliper overhaul, brake pad replacement, brake fluid flush and bleeding, disc inspection.
Electrical System:
Wiring diagrams, lighting system troubleshooting, battery maintenance and testing, starter motor inspection, charging system (stator, regulator/rectifier) testing.
Cooling System:
Radiator inspection and cleaning, coolant flush and refill, water pump service, thermostat operation.
Frame And Bodywork:
Frame inspection for cracks or damage, fairing removal and installation, seat servicing, handlebar and control lever adjustment/replacement.
Routine Maintenance:
Oil and filter change, air filter cleaning/replacement, chain adjustment and lubrication, brake inspection, tire pressure checks, general bolt torque checks.
Troubleshooting:
Systematic diagnostic procedures for common starting, running, and electrical issues.
Component Rebuilds:
Detailed step-by-step instructions for engine, transmission, suspension, and brake component overhauls.
Adjustments:
Carburetor jetting, clutch and throttle cable free play, suspension settings.
Special Tools:
Identification and usage of specialized tools required for specific procedures.
Depth:
Comprehensive from basic maintenance to full engine and chassis rebuilds, including detailed specifications and torque values.
Displacement:
193 cc (approx.)
Bore X Stroke:
62.5 mm x 65 mm (typical for this displacement)
Cooling System:
Liquid-cooled
Cylinder Configuration:
Single-cylinder
Power Output:
Approx. 35-40 HP (varies by specific tune and year)
Torque Output:
Data typically not specified in owner's manuals, but significant for its class.
Compression Ratio:
Typically around 8.5:1 to 9.0:1
Carburetor Type:
Keihin PWK 36 or similar
Fuel Type:
Unleaded gasoline, minimum 91 octane (RON+MON)/2
Fuel Mixture:
Pre-mix (manual will specify oil-to-fuel ratio, typically 40:1 or 50:1).
Length:
Approx. 2170 mm (typical)
Width:
Approx. 810 mm (typical)
Height:
Approx. 1230 mm (typical)
Wheelbase:
Approx. 1480 mm (typical)
Dry Weight:
Approx. 105 kg (typical)
Fuel Tank Capacity:
Approx. 8 liters (typical)
Oil Capacity Engine:
For 2-stroke, typically refers to transmission oil capacity. Manual will specify for gearbox.
Coolant Capacity:
Manual will specify precise capacity.
Safety Certifications:
As a competition-oriented off-road motorcycle, primarily designed for closed-course use, traditional automotive safety ratings (e.g., NHTSA, Euro NCAP) are not applicable. Compliance with noise and emissions regulations for off-road vehicles would be relevant.
Braking System:
Hydraulic disc brakes front and rear for effective stopping power in off-road conditions.
Ergonomics:
Designed for rider control and comfort during demanding off-road riding, including handlebar position and footpeg placement.
Engine Oil Change:
Refer to manual, typically every 10-15 hours of riding for a 2-stroke.
Air Filter Cleaning:
Refer to manual, often every 5-10 hours of riding or as needed based on conditions.
Spark Plug Replacement:
Refer to manual, typically every 25-50 hours of riding.
Chain Lubrication:
Refer to manual, recommended every ride or every few hours depending on conditions.
Fork Oil Change:
Refer to manual, often every 30-50 hours of riding for optimal suspension performance.
Engine Oil Type:
High-quality 2-stroke premix oil (specific brand/type recommended in manual, e.g., Motorex).
Transmission Oil Type:
Manual will specify gearbox oil grade and type (e.g., SAE 75W/90 or specific KTM recommendation).
Coolant Type:
Ethylene glycol based coolant with corrosion inhibitors (specified by manual).
Brake Fluid Type:
DOT 4 or DOT 5.1 (specified by manual).
Common Wear Items:
Piston rings, clutch plates, wheel bearings, linkage bearings, fork seals, spark plugs, and air filters are common wear items on high-performance off-road motorcycles.
Two Stroke Specifics:
Proper fuel-to-oil ratio is critical to prevent engine damage. Carburetor cleaning and jetting can be sensitive to altitude and temperature changes.
Brand Focus:
KTM has a long history and strong reputation in off-road motorsports, particularly in motocross and enduro racing, dating back to the 1950s.
Enduro Lineup:
The EXC line represents KTM's commitment to versatile off-road motorcycles suitable for racing and trail riding. The 200 EXC was part of a range of displacements designed to offer different power characteristics and rider experiences.
Manufacturing Location:
Austria
Era Context:
This generation of KTM EXC models benefited from continuous development in chassis design, suspension technology, and engine performance, reflecting KTM's racing successes.
