Segment:
Off-road, Enduro
Competitors 1999-2003:
Husqvarna WR250, Yamaha YZ250 WR, Suzuki RMX250, Honda CR250R E
Bike Focus:
Lightweight, agile, powerful two-stroke performance for off-road competition and trail riding.
Systems Covered:
Engine, Transmission, Chassis, Electrical System, Suspension, Brakes, Fuel System, Cooling System, Exhaust System, Bodywork, Troubleshooting, Maintenance, Specifications
Page Count:
Hundreds of pages (specific count not provided, but described as comprehensive)
Manual Type:
Factory Service Repair Manual
Engine Overhaul:
Complete engine disassembly, inspection, repair, and reassembly procedures for the 200cc two-stroke engine.
Transmission Service:
Detailed instructions for gearbox maintenance, clutch service, and troubleshooting transmission issues.
Chassis And Suspension:
Procedures for fork and shock absorber service, linkage maintenance, frame inspection, and wheel bearing replacement.
Electrical Diagnostics:
Wiring diagrams, troubleshooting guides for ignition, lighting, and charging systems, as well as component testing.
Brake System Maintenance:
Guidance on brake pad replacement, caliper service, master cylinder maintenance, and bleeding procedures.
Fuel And Carburetion:
Detailed information on carburetor adjustment, cleaning, jetting, and fuel system component inspection.
Frame And Bodywork:
Repair procedures for plastic body panels, seat, fuel tank, and frame components.
Routine Maintenance:
Scheduled maintenance tasks, oil changes, filter replacements, chain adjustment, and spark plug service.
Troubleshooting Guides:
Systematic approaches to diagnosing and resolving common operational problems and failures.
Major Repairs:
Instructions for significant component overhauls and replacements, including engine rebuilds.
Component Disassembly Reassembly:
Step-by-step guides for taking apart and putting back together all major motorcycle systems.
Engine Tuning:
Basic tuning advice, carburetor jetting, and exhaust modification considerations.
Wheel And Tire Service:
Information on tire changes, wheel balancing, and spoke tensioning.
Diagnostic Charts:
Flowcharts and tables to systematically diagnose common problems.
Depth Of Information:
Comprehensive factory-level detail suitable for professional technicians and experienced DIY mechanics.
Torque Specifications:
Precise torque values for all critical fasteners.
Clearances And Tolerances:
Detailed specifications for engine component clearances, bearing tolerances, etc.
Wiring Diagrams:
Full electrical system schematics for troubleshooting and repairs.
Engine Type:
2-stroke, Single Cylinder
Displacement:
192.7 cc (11.77 cu in)
Bore X Stroke:
62.5 mm x 62.4 mm (2.46 in x 2.46 in)
Cooling System:
Liquid-cooled
Carburetor:
Keihin PWK 39
Horsepower Approx:
~40 hp @ 8,500 rpm (Estimate, official figures vary)
Torque Approx:
~35 Nm @ 7,500 rpm (Estimate, official figures vary)
Fuel Type:
Unleaded gasoline with 2-stroke oil pre-mix
Fuel Ratio:
1:40 or 1:50 (recommended by KTM)
Ignition Type:
Digital CDI ignition system
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-disc clutch, hydraulically operated
Gear Ratios:
Specific ratios available in manual, typically focused on off-road performance.
Transmission Oil Spec:
KTM recommends specific gearbox oil, often a SAE 80W/90 API GL-4.
Oil Change Interval:
Refer to manual; typically every 15-25 hours of riding for gearbox oil.
Top End Rebuild Interval:
Highly variable based on use; can range from 50-100+ hours for piston/rings, and 100-200+ hours for a full engine rebuild.
Engine Oil Type:
Premix 2-stroke oil, specific grade and brand recommendations in manual.
Coolant Type:
Ethylene glycol-based antifreeze mixture.
Brake Fluid Type:
DOT 4 brake fluid.
Fork Oil Type:
Specific fork oil weight and level specified in the manual (e.g., WP suspension fluid).
Common Wear Items:
Piston rings, clutch plates, wheel bearings, swingarm pivot bearings, steering head bearings, fork seals, exhaust packing.
Potential Problems:
Carburetor jetting sensitivity to altitude and temperature, reed valve wear, kickstart mechanism wear.
