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.
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.
Searchable Text:
Yes (typically, dependent on original scan quality)
Quality:
High resolution for clear diagrams and text
Binding:
N/A (Digital PDF Download)
Paper:
N/A (Digital PDF Download)
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)
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)
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)
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.
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.
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.
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.
