Market Position:
The KTM 200 EXC was positioned as a competitive entry-level to mid-range off-road motorcycle, popular for enduro riding and trail exploration. It offered a potent 2-stroke engine known for its crisp power delivery in a lightweight chassis.
Competitive Analysis:
Competed against other 200cc to 250cc off-road machines from manufacturers like Yamaha (WR200), Honda (CR250, though different class), Suzuki (RM250, different class), and Husqvarna. KTM's strength was often its focused off-road performance and aggressive styling.
Key Features:
Lightweight and agile chassis, strong 2-stroke engine performance, robust suspension, KTM's off-road pedigree, often equipped with readily adjustable components for trail riding.
Engine Mechanical:
Engine disassembly, assembly, internal component inspection and replacement (pistons, rings, crankshaft, bearings, cylinder, head), valve timing (where applicable for 2-stroke port timing), lubrication system.
Engine Fuel System:
Carburetor disassembly, cleaning, adjustment, jetting information, fuel tank, fuel lines, fuel filter maintenance.
Engine Ignition System:
Ignition coil, CDI unit, spark plug specifications, troubleshooting ignition faults.
Transmission Drivetrain:
Clutch operation, adjustment, disassembly and assembly, gearbox internal inspection, gear shift mechanism, chain and sprockets maintenance.
Suspension:
Front fork maintenance, seal replacement, oil changes, rear shock absorber inspection and service, linkage maintenance.
Brakes:
Front and rear brake system service, caliper inspection, pad replacement, brake fluid flush and bleed, master cylinder and slave cylinder maintenance.
Cooling System:
Radiator maintenance, coolant type and capacity, fan operation (if applicable), hose inspection.
Electrical System:
Wiring diagrams, lighting system, battery maintenance, starter system (if electric start), fuse replacement, troubleshooting electrical circuits.
Chassis Frame:
Frame inspection for damage, steering head bearing maintenance, swingarm bearing service.
Bodywork:
Fairing removal and installation, seat, fenders, and other body panel maintenance.
Routine Maintenance:
Oil changes, filter replacements, chain lubrication and adjustment, spark plug checks, air filter cleaning/replacement.
Troubleshooting Diagnostics:
Common problems and their solutions, diagnostic charts for engine performance, electrical faults, and running issues.
Major Repairs:
Engine rebuilds, transmission overhauls, suspension component replacements.
Component Overhaul:
Detailed instructions for overhauling carburetors, brake calipers, and other wear-prone components.
Specifications Settings:
Torque specifications for all fasteners, engine tuning settings, suspension sag adjustments.
Technical Depth:
Comprehensive, covering from basic maintenance to full engine and chassis overhauls. Suitable for home mechanics and professional technicians.
Engine Type:
2-stroke, Single Cylinder
Displacement:
Approximately 193-200cc (specific value confirmed in manual)
Bore X Stroke:
Details would be provided in the manual, typically around 62.5mm x 65mm for this displacement.
Cooling System:
Liquid-cooled
Horsepower:
Estimated 30-35 HP (specific dyno figures would vary and be in manual)
Torque:
Details would be in the manual, typically around 20-25 Nm.
Carburetor Type:
Likely a Keihin PWK or similar high-performance 2-stroke carburetor (e.g., 35mm or 38mm).
Fuel Type:
Unleaded gasoline with appropriate 2-stroke oil pre-mix (specific ratio in manual)
Oil Mixture Ratio:
Typically 40:1 or 50:1, to be confirmed in the manual.
Oil Change Interval:
Recommended every 10-15 hours of riding, or as specified for engine oil in the manual.
Air Filter Cleaning:
Recommended every 5-10 hours of riding, or more frequently in dusty conditions, as detailed in the manual.
Spark Plug Replacement:
Inspect every 20-30 hours, replace as needed based on condition, specific plug type and gap in manual.
Chain Lubrication Adjustment:
Lubricate every fuel fill-up, adjust tension as needed per manual's specifications (typically 20-30mm of slack).
Engine Oil Type:
Specific 2-stroke engine oil (e.g., Motorex or equivalent) for pre-mix, specific type for gearbox oil (e.g., SAE 75W/80W).
Coolant Type:
Ethylene glycol-based coolant with corrosion inhibitors, mixed with distilled water (specific ratio in manual).
Brake Fluid Type:
DOT 4 hydraulic brake fluid (confirm specific type in manual).
Known Issues:
As with many 2-strokes of this era, potential issues include piston ring wear, carburetor tuning sensitivity to altitude/temperature, clutch wear, and general maintenance related to off-road use (e.g., suspension seals, bearings).
Typical Wear Items:
Piston and rings, clutch plates, wheel bearings, steering head bearings, brake pads, chain and sprockets.
Brand Heritage:
KTM, founded in Austria, has a long-standing reputation for producing high-performance off-road motorcycles, earning the nickname 'Ready to Race'. Their focus on motocross and enduro racing has deeply influenced their production models.
Model Evolution:
The EXC line has seen continuous development. The 200 EXC was part of a generation of liquid-cooled, performance-oriented 2-strokes that KTM refined throughout the late 1990s and early 2000s. Updates typically included chassis refinements, engine tuning, and suspension improvements.
Production Period:
The 200 EXC model was produced for several years within this timeframe, with annual updates to specifications and graphics.
Manufacturing Location:
Primarily Austria
