Segment:
Lightweight Enduro/Off-road Motorcycle
Target Audience:
Enthusiasts, amateur racers, trail riders seeking capable and agile off-road performance.
Key Competitors:
Yamaha WR200, Kawasaki KDX200, Suzuki RM200 (period specific)
Vehicle Attributes:
Lightweight, agile handling, potent 2-stroke engine, capable off-road suspension.
Benefit To Owner:
Empowers owners to perform comprehensive maintenance, diagnostics, and repairs, reducing reliance on professional service.
Engine:
Engine disassembly, assembly, tuning, valve clearance, piston/ring replacement, cylinder head service, cooling system.
Fuel System:
Carburetor overhaul and adjustment, fuel pump, fuel lines, fuel tank servicing.
Ignition System:
Ignition timing, spark plug selection and gap, ignition coil testing, CDI unit diagnostics.
Transmission:
Gearbox disassembly and reassembly, clutch operation and adjustment, shift mechanism repair.
Suspension:
Front fork service (oil change, seal replacement, damping adjustments), rear shock absorber servicing and replacement, linkage maintenance.
Brakes:
Hydraulic brake system service (bleeding, pad replacement, caliper overhaul, master cylinder repair), disc and rotor specifications.
Electrical System:
Wiring diagrams, starter motor, lighting system, battery maintenance, charging system (alternator/stator testing), fuses and relays.
Frame And Body:
Frame inspection, body panel removal and installation, seat servicing, handlebar and control adjustments.
Wheels And Tires:
Wheel bearing maintenance, spoke tensioning, tire pressure recommendations, rim specifications.
Exhaust System:
Exhaust pipe and silencer inspection and replacement, gasket specifications.
Maintenance:
Regular service intervals, oil changes, filter replacements, chain lubrication and adjustment, spark plug checks.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems, fault finding charts.
Repair:
Step-by-step instructions for component removal, replacement, and reassembly for all major systems.
Overhaul:
Complete engine, carburetor, and suspension component overhaul procedures.
Adjustments:
Carburetor jetting and idle speed, clutch lever free play, brake lever play, suspension sag.
Specifications Setting:
Torque values for critical fasteners, valve clearances, ignition timing, chain slack.
Depth:
Comprehensive from basic rider maintenance to complete engine rebuilds and electrical system diagnostics.
Diagnostics:
Detailed electrical troubleshooting guides with wiring diagrams and component testing procedures.
Special Tools:
Lists and descriptions of specialized tools required for specific procedures (e.g., flywheel puller, clutch holding tool).
Type:
2-Stroke, Single Cylinder, Liquid-Cooled
Displacement:
193 cc (approximate, confirm with manual)
Bore X Stroke:
e.g., 66.0 mm x 57.8 mm (confirm with manual)
Compression Ratio:
e.g., 8.5:1 (confirm with manual)
Horsepower:
Approx. 30-35 HP (estimate, actual may vary by market and tune)
Torque:
Approx. 25-30 Nm (estimate, actual may vary)
Carburetor:
Mikuni VM Series (e.g., VM38SS or similar, confirm with manual)
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil pre-mix (specify ratio from manual)
Type:
Pre-mix or Autolube system (confirm with manual)
Oil Change:
Every 10-15 hours of operation or as specified in manual (typically more frequent for off-road).
Air Filter Cleaning:
After every few rides or in dusty conditions, as detailed in manual.
Spark Plug Replacement:
e.g., Every 30-40 hours or as needed (confirm with manual).
Chain Maintenance:
Lubricate and adjust chain at frequent intervals, especially after riding in wet or dirty conditions.
Top End Rebuild:
Service interval depends heavily on usage, manual provides guidance on piston ring/piston inspection.
Engine Oil:
Refer to manual for exact grade (e.g., Motorex, Castrol) and 2-stroke oil mix ratio. Common grades like SAE 10W/40, API SG.
Coolant:
Ethylene glycol-based coolant with corrosion inhibitors (confirm specific type and mixture ratio from manual).
Brake Fluid:
DOT 4 recommended (confirm from manual).
Fork Oil:
Specific viscosity and level required for front forks (e.g., SAE 7.5W, specific level from manual).
Common Wear Items:
Clutch plates, piston rings, fork seals, wheel bearings, chain and sprockets due to off-road stress.
Carburetor Tuning:
May require periodic adjustment based on altitude, temperature, and modifications. Manual provides base settings.
Cooling System Maintenance:
Importance of regular coolant checks and flushes to prevent overheating in demanding conditions.
Manufacturer Origin:
Austria
Brand Focus:
Performance-oriented motorcycles, particularly in off-road disciplines (motocross, enduro, rally).
Lineage:
Part of KTM's extensive range of off-road motorcycles, building on earlier 2-stroke enduro models.
Key Innovations:
KTM's reputation for robust engines, advanced suspension, and aggressive styling.
Production Period:
Models produced in the late 1990s, representing a specific era of KTM's development.
