Segment:
Enduro / Off-Road Competition Motorcycle
Target User:
Enthusiast riders participating in enduro events, trail riding, and off-road competitions.
Competitors Circa 1999-2003:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (2-stroke counterparts); potentially GasGas EC250, Husqvarna WR250.
Engine Type:
2-stroke, liquid-cooled, single-cylinder (distinct from larger 4-stroke models).
Performance Focus:
Lightweight, agile, potent power delivery for off-road use.
Suspension Brand:
Often equipped with WP Suspension components, a hallmark of KTM's performance.
Supported Model Years:
1999, 2000, 2001, 2002, 2003
Supported Variants:
All Models (assumed to cover all 200 EXC configurations within these years)
Estimated Page Count:
Detailed page count not specified, but typical for a comprehensive workshop manual of this era would be 300-600 pages.
Type:
Workshop Repair Service Manual
Language:
Likely English, but confirmation with seller advised for specific edition.
Engine Mechanical:
Complete engine assembly, disassembly, overhaul, top-end (cylinder, piston, rings, head), bottom-end (crankshaft, connecting rod, bearings), valve train, lubrication system, cooling system.
Fuel System:
Carburetor specifications, adjustment, cleaning, and overhaul. Fuel tank, fuel lines, fuel petcock operation and maintenance.
Ignition System:
CDI unit, spark plug specifications, ignition timing, troubleshooting of ignition faults.
Transmission Drivetrain:
Gearbox assembly and disassembly, clutch operation and adjustment, chain and sprockets maintenance, lubrication.
Suspension:
Front fork (WP Suspension likely) disassembly, service, seal replacement, oil level and type. Rear shock absorber service, adjustments, and rebuild procedures.
Brakes:
Front and rear brake caliper service, pad replacement, fluid bleeding, master cylinder overhaul. Brake disc specifications.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, charging system (stator, regulator/rectifier), starter system (if applicable, though typically kick-start for this model), fuses, switches, and control units.
Frame Chassis:
Frame inspection, headstock bearings, swingarm service, wheel bearings, spokes and rims maintenance, chain adjustment.
Bodywork Plastics:
Removal and installation of body panels, seat, fuel tank, fenders.
Troubleshooting:
Diagnostic procedures for common problems, fault finding charts for engine, electrical, and mechanical issues.
Preventative Maintenance:
Scheduled maintenance tasks, lubrication points, cleaning procedures, periodic checks.
Disassembly Assembly:
Step-by-step instructions for complete component disassembly and reassembly.
Repair Rebuild:
Detailed procedures for repairing and rebuilding major components like the engine, transmission, and suspension.
Adjustments:
Carburetor settings, clutch lever free play, chain tension, suspension preload, and damping adjustments.
Diagnostic Tests:
Methods for diagnosing electrical faults, engine performance issues, and mechanical problems.
Depth:
Comprehensive, covering everything from basic rider maintenance to full engine rebuilds and advanced troubleshooting.
Target Audience:
Professional motorcycle technicians and experienced DIY enthusiasts.
Specificity:
Highly specific technical data, torque specifications, clearance measurements, and detailed schematics.
Searchability:
Typically searchable text within PDF, allowing for quick information retrieval.
Printable:
Yes, designed for printing specific sections or the entire manual.
Quality:
Depends on the original source scanned. High-quality PDF scans are expected for professional manuals.
Binding:
N/A (PDF format, but original manual would be saddle-stitched or perfect bound).
Paper:
N/A (PDF format, but original manual typically on durable paper stock).
Configuration:
Single-cylinder, 2-stroke
Displacement:
193cc (95 x 65.5 mm bore x stroke)
Cooling System:
Liquid-cooled
Induction:
Reed valve induction, carburetor fed.
Ignition:
CDI (Capacitor Discharge Ignition)
Power Output:
Estimated 35-40 HP (subject to specific model year tuning and regional variations).
Torque Output:
Not explicitly stated, but characterized by strong mid-range torque.
Carburetor Model:
Likely Keihin PWK (e.g., PWK 35) or similar performance carburetor.
Fuel Type:
Unleaded gasoline (minimum 95 octane recommended) mixed with 2-stroke oil.
Fuel Mix Ratio:
Typically 1:40 or 1:50 (oil to gasoline), consult manual for specific ratio and oil type.
2 Stroke Oil Type:
High-quality 2-stroke motorcycle oil (e.g., JASO FD certified).
Frame Type:
Chromium-molybdenum steel, perimeter type.
Wheelbase:
Approximately 1460 mm (57.5 inches) - subject to slight variations.
Ground Clearance:
Typically high for off-road clearance, specific figure in manual.
Dry Weight:
Around 100-105 kg (220-231 lbs) - highly competitive for its class.
Fuel Tank Capacity:
Approximately 9-12 liters (2.4-3.2 US gallons).
Front Travel:
Typically 280-300 mm (11-11.8 inches).
Rear Travel:
Typically 290-310 mm (11.4-12.2 inches).
Oil Change Interval:
Engine oil for gearbox: As per manual, typically every 15-20 hours of operation or annually. Transmission fluid type specified in manual (e.g., SAE 10W/30 or 15W/40).
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions, often every few rides.
Spark Plug Replacement:
Intervals vary, typically 20-40 hours depending on usage and plug type. Manual will specify recommended plug and gap.
Top End Rebuild:
Recommended every 80-120 hours for competitive use, or based on performance degradation. Manual will provide piston and ring wear limits.
Coolant:
Ethylene glycol-based antifreeze mixture. Manual will specify coolant type and mixture ratio.
Fork Oil:
Specific viscosity (e.g., SAE 5W, 7.5W, 10W) and volume per fork leg. WP suspension oil specified.
Brake Fluid:
DOT 4 recommended for hydraulic brake systems.
Power Valve Sticking:
Common in 2-strokes if not properly maintained; requires cleaning to ensure optimal power delivery. Manual covers adjustment and cleaning.
Clutch Wear:
Clutch plates and springs can wear over time, requiring replacement. Manual details wear limits and replacement procedure.
Carburetor Jetting:
Can be sensitive to altitude and temperature changes; manual provides base jetting and tuning guidance.
Suspension Seals:
Fork and shock seals can leak due to hard use; manual details seal replacement.
Ktm Offroad Focus:
KTM has a long and successful history in off-road racing (Motocross, Enduro, Dakar Rally), with a reputation for performance and durability.
Exc Lineage:
The EXC (Enduro Cross-Country) line represents KTM's commitment to competition-oriented off-road motorcycles. The 200 EXC was a popular choice for riders seeking a lightweight, powerful, and agile machine.
Engine Development:
The 200cc 2-stroke engine was developed to offer a potent power-to-weight ratio, bridging the gap between smaller trail bikes and larger displacement competition machines.
Manufacturing Location:
Primarily Austria, KTM's traditional manufacturing base.
Significance Of Years:
1999-2003 marks a specific generation of the 200 EXC, likely with incremental updates during these years. The manual covers this core period.
