Model:
200 EXC EXC SIX DAYS
Production Years:
1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006
Chassis Code Range:
Likely specific to generation and sub-model, consult manual for precise identification
Engine Code Range:
Likely specific to generation and sub-model, consult manual for precise identification
Market Position:
Enduro and Off-Road Competition/Enthusiast Segment
Competitors:
Yamaha YZ250, Honda CR250R, Suzuki RM250, Kawasaki KX250 (2-stroke variants from the era)
Key Features:
Lightweight chassis, potent 2-stroke engine, potent suspension, optimized for off-road performance, 'SIX DAYS' edition denotes specialized components and graphics from international enduro events.
Engine Systems:
Engine overhaul, top-end, bottom-end, lubrication, cooling, fuel delivery, ignition, exhaust
Transmission Systems:
Gearbox, clutch, shifting mechanism, lubrication
Chassis Systems:
Frame, suspension (front and rear), steering, brakes (hydraulic), wheels, tires
Electrical Systems:
Wiring diagrams, lighting, ignition system components, battery, charging system, controls
Bodywork And Plastics:
Fairings, seat, body panels, graphics (SIX DAYS specific details likely)
Maintenance Procedures:
Routine maintenance, oil changes, filter replacements, chain adjustment, brake bleeding, spark plug replacement
Repair Procedures:
Complete engine rebuild, transmission overhaul, suspension fork service, brake caliper rebuild, electrical component replacement
Troubleshooting Guides:
Diagnostic flowcharts, common problem identification and resolution
Torque Specifications:
Detailed torque values for all critical fasteners
Special Tools:
Listing and usage of specialized tools required for specific procedures
Depth:
Comprehensive, covering from basic maintenance to full engine and chassis overhauls, suitable for professional mechanics and experienced DIY enthusiasts
Displacement:
193 cc (approximate for 200 EXC designation)
Bore X Stroke:
Consult manual for exact specifications (typically around 62.5 mm x 65 mm)
Cooling System:
Liquid-cooled
Horsepower:
Estimated 35-40 HP (subject to specific tuning and year)
Torque:
Consult manual for exact specifications
Carburetor Type:
Typically Keihin PWK (e.g., 35mm)
Fuel Type:
Unleaded gasoline with 2-stroke oil mixture (premix or autolube system)
Lubrication Type:
Premix or separate autolube injection system (confirm with manual)
Frame Type:
Chromoly steel, central-tube, single-cradle, perimeter frame
Wheelbase:
Consult manual for exact specifications (typically around 1460 mm)
Seat Height:
Consult manual for exact specifications (typically around 960 mm)
Dry Weight:
Consult manual for exact specifications (typically around 95-105 kg)
Fuel Tank Capacity:
Consult manual for exact specifications (typically around 8-10 Liters)
Front Wheel Size:
21 inch
Front Tire Size:
Typically 80/100-21
Rear Tire Size:
Typically 100/100-18 or 110/100-18
Front Brake Type:
Hydraulic disc brake, twin-piston caliper
Rear Brake Type:
Hydraulic disc brake, single-piston caliper
Safety Ratings:
N/A (Off-road motorcycles typically not subjected to road-vehicle safety rating tests like NHTSA or Euro NCAP)
Active Safety:
Powerful hydraulic disc brakes, responsive suspension, ergonomic controls
Passive Safety:
Sturdy frame construction, impact-absorbing components (e.g., handlebars, levers if designed for it)
Oil Change Interval:
Consult manual for exact intervals; typically every 10-15 hours of riding or annually.
Air Filter Cleaning:
Frequent cleaning recommended, especially in dusty conditions (check manual for specific guidance).
Spark Plug Replacement:
Consult manual; typically every 20-30 hours of riding.
Top End Rebuild:
Consult manual; recommended based on operating hours (e.g., 50-100 hours for piston/rings, potentially more for cylinder).
Engine Oil Type:
Specific 2-stroke premix oil, high quality, JASO FD or equivalent recommended. Consult manual for exact specifications and mixing ratio if applicable.
Gearbox Oil Type:
High-quality motorcycle gear oil, e.g., SAE 75W/80 or 80W/90. Consult manual for specific KTM recommendation (e.g., Motorex Gear Oil).
Coolant Type:
Ethylene glycol-based antifreeze coolant mixture. Consult manual for specific type and mixture ratio.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Common Issues Overview:
Potential issues common to high-performance 2-strokes of this era include jetting sensitivity, wear on clutch plates, suspension seal leaks, and regular maintenance of the power valve system.
Power Valve Maintenance:
Crucial for optimal performance. Regular cleaning and inspection for carbon buildup and proper function are essential.
Carburetor Jetting:
Requires careful attention to altitude, temperature, and humidity for optimal performance and engine longevity. Manual will provide baseline jetting specs.
Brand Heritage:
KTM has a strong heritage in off-road motorsports, particularly enduro and motocross, renowned for its 'Ready to Race' philosophy.
Model Evolution Context:
The EXC line represents KTM's enduro offerings. The 200 EXC was a popular choice for riders seeking a powerful yet manageable 2-stroke for various off-road disciplines. The 'SIX DAYS' designation celebrates KTM's success in the International Six Days Enduro (ISDE) and typically included upgraded components like special graphics, sometimes different exhaust systems, or enhanced suspension.
Production Period:
1999-2006 for this specific generation covered by the manual.
Manufacturing Location:
Austria (Primary KTM production)
Brand Recognitions:
KTM has numerous awards and championships in various off-road racing disciplines, reflecting the performance and durability of their models.
Model Ratings:
Subjective reviews and rider feedback often praised the 200 EXC for its power-to-weight ratio and handling capabilities in its class.
Certifications:
N/A (Not applicable to this type of vehicle/manual)
