🏷️ Basic Information

Make:

KTM

Model:

200 EXC

Model Code:

200 EXC

Years Covered:

1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006

Generation Identifier:

Early EXC 200 Models

👋 Introduction

Segment:

Performance Off-Road Motorcycle (Enduro/Cross Country)

Target Audience:

Enthusiast riders, amateur racers, and professional mechanics requiring detailed repair and maintenance information.

Competitors Era:

Suzuki RM250, Yamaha YZ250, Honda CR250 (2-stroke), Husqvarna WR250, GasGas EC250 of the same period.

Brand Focus:

KTM's reputation for high-performance, race-bred machinery.

Model Advantage:

The 200 EXC offered a potent blend of 125 agility and 250 power in a lightweight package, making it a niche but highly capable machine.

Manual Value Proposition:

Provides essential technical data for maintaining and repairing a performance off-road motorcycle, crucial for its longevity and optimal function.

📋 Manual Details

Coverage Scope:

Complete Factory Service Repair

Page Count Estimate:

Hundreds of Pages (Specific count not provided, but indicative of comprehensive coverage)

Manual Type:

Factory Service Repair Manual

Language:

English (Implied by product description and typical market)

Format:

PDF Download

📖 Manual Coverage

Engine System:

Detailed disassembly, assembly, inspection, and repair of all engine components including top-end (cylinder, piston, rings, head), bottom-end (crankshaft, connecting rod, bearings), cooling system, lubrication system, and power valve operation.

Transmission And Drivetrain:

Complete coverage of gearbox operation, clutch system (including wet multi-plate clutch), shift mechanism, chain and sprocket maintenance, and gearbox oil specifications.

Fuel System:

Carburetor (likely Keihin PWK based on era) overhaul, adjustment, jetting information, fuel lines, petcock, and tank maintenance.

Electrical System:

Wiring diagrams, ignition system (CDI, coil, spark plug), lighting, charging system (stator, regulator/rectifier), battery, and starter system (if applicable).

Suspension System:

Front fork (WP USD forks typical) disassembly, seal replacement, oil type and level specifications, damping adjustments, and rear shock absorber (WP PDS or similar) servicing and adjustments.

Braking System:

Front and rear hydraulic brake system maintenance, caliper overhaul, master cylinder service, brake fluid type and bleeding procedures, pad replacement, and rotor inspection.

Cooling System:

Radiator, hoses, water pump, and coolant specifications, bleeding procedures, and system pressure testing.

Chassis And Frame:

Frame inspection, steering head bearing service, swingarm and linkage maintenance, footpeg and lever adjustments, and general chassis component inspection.

Bodywork And Plastics:

Removal and installation of fenders, seat, fuel tank, side panels, and graphics.

Maintenance Procedures:

Regular service tasks, including oil changes, filter replacements (air and oil/screen), spark plug checks, chain adjustment, brake fluid changes, and tire pressure checks.

Troubleshooting Guides:

Systematic diagnostic procedures for common problems, including starting issues, engine performance problems, electrical faults, and suspension malfunctions.

Engine Rebuild Procedures:

Comprehensive instructions for top-end rebuilds, bottom-end overhauls, and complete engine disassembly and reassembly.

Suspension Servicing:

Detailed steps for fork seal replacement, damper rod service, and rear shock absorber rebuilds.

Electrical Diagnostics:

Fault finding based on symptoms, circuit testing, and component testing using multimeters.

Brake System Maintenance:

Bleeding procedures, caliper piston service, and master cylinder overhaul.

Carburetor Tuning And Rebuild:

Jetting recommendations, float height adjustment, and complete carburetor disassembly and cleaning.

Diagnostic Capability:

Advanced diagnostics for complex issues, including electrical system troubleshooting and performance tuning.

Repair Scope:

From basic routine maintenance to complete engine and gearbox rebuilds, including component-level repairs.

Specifications Detail:

Includes critical torque specifications, clearances, fluid levels, and diagnostic parameters for all major systems.

Wiring Diagrams Completeness:

Comprehensive and detailed wiring diagrams essential for electrical system diagnostics and repairs.

📊 Manual Specifications

File Format:

PDF

Searchability:

Typically searchable text content for easy navigation (dependent on PDF creation).

Print Quality Recommendation:

High resolution, suitable for printing all pages for workshop use.

Binding Type For Print:

Digital Download (no physical binding)

Paper Type For Print:

Standard paper (user choice for printing)

⚙️ Engine Specifications

Engine Type:

Two-Stroke Single Cylinder

Displacement:

193 cc

Bore X Stroke:

62.5 mm x 65 mm (Typical for this model)

Cooling System:

Liquid-Cooled

Power Valve System:

KTM's PowerJet or similar electronic/mechanical exhaust power valve system.

Starting System:

Kickstart

Horsepower Estimate:

Approx. 35-40 HP (at crankshaft, subject to tuning and specific year)

Torque Estimate:

Approx. 25-28 Nm (at crankshaft, subject to tuning and specific year)

Carburetor Model:

Keihin PWK 35 (Common fitment for this era)

Fuel Type:

Unleaded Premium Gasoline (95 Octane or higher recommended)

Premix Ratio:

50:1 or 40:1 (using high-quality 2-stroke racing oil, as specified in manual)

🔧 Transmission

Transmission Type:

6-Speed Constant Mesh

Clutch Type:

Wet Multi-Plate Clutch

Final Drive:

Chain Drive

Gearbox Oil Type:

SAE 80W/90 Hypoid Gear Oil (KTM recommends specific grades, e.g., Motorex Gear Oil)

Gearbox Oil Capacity:

Approx. 0.7 Liters (0.74 US qt) (Verify in manual)

📐 Dimensions

Wheelbase:

Approx. 1455 mm (57.3 in) (Subject to year variation)

Seat Height:

Approx. 960 mm (37.8 in) (Subject to year variation)

Dry Weight:

Approx. 102 kg (225 lbs) (Subject to year variation)

Fuel Capacity:

Approx. 9 Liters (2.4 US gal) (Subject to year variation)

🛡️ Safety Features

Safety Ratings:

Not applicable for off-road motorcycles in the same way as passenger vehicles. Focus on mechanical integrity and rider protection.

Active Safety Features:

Powerful hydraulic disc brakes (front and rear) for effective stopping power.

Passive Safety Features:

Robust frame construction, compliant suspension for terrain absorption, and rider control ergonomics.

💡 Technology Features

Infotainment System:

Not applicable. Focus is on performance and functionality.

Driver Assistance Features:

Not applicable. Focus is on rider control.

Connectivity Features:

Not applicable.

🔧 Maintenance

Engine Oil Change Interval:

Check and top-up before every ride. Change gearbox oil every 15-25 hours of riding or annually. (Refer to manual for precise intervals).

Air Filter Cleaning:

Clean after every 5-10 hours of riding, or more frequently in dusty conditions.

Spark Plug Inspection:

Inspect and clean/replace every 20-30 hours of riding.

Chain Lubrication Adjustment:

Lubricate chain every 500 km (300 miles) or more frequently if exposed to water/mud. Adjust tension as needed, checking for approximately 20-30mm of slack.

Coolant Type:

Ethylene Glycol based antifreeze with corrosion inhibitors (e.g., Motorex Coolant M3.0 or equivalent).

Brake Fluid Type:

DOT 4 Hydraulic Brake Fluid (KTM recommends specific grades, e.g., Motorex Brake Fluid DOT 4).

Fork Oil Type:

Specific suspension fork oil with appropriate viscosity (e.g., WP Suspension Fluid 5W, or aftermarket equivalents like Maxima, Bel-Ray). Manual will specify viscosity and volume.

Common Wear Items:

Piston rings, clutch plates, wheel bearings, steering head bearings, fork seals, and swingarm bearings are typical wear items on high-performance off-road bikes.

Power Valve Sticking:

The power valve mechanism can accumulate carbon deposits and become sticky if not maintained, affecting engine performance. Regular cleaning is essential.

Suspension Seals:

Fork seal leaks and shock seal failures can occur due to harsh riding conditions and require regular inspection and replacement.

📚 Vehicle History

Brand Origins:

KTM is an Austrian manufacturer founded in 1934, renowned for its off-road motorcycle racing heritage.

Exc Lineage:

The EXC line represents KTM's dedication to the enduro and cross-country racing segment, evolving through various engine sizes and technological updates.

200Cc Segment:

KTM's 200cc offerings have historically provided a nimble and powerful option for riders seeking a balance between the small displacement and the larger two-strokes.

Production Location:

Austria (Primary)

🏆 Awards & Recognition

Brand Recognition:

KTM has consistently received acclaim in off-road racing disciplines, including national and international championships.

Model Reviews Era:

Contemporary reviews often praised the 200 EXC for its surprising power-to-weight ratio, agile handling, and KTM's robust componentry.

Certifications:

Not applicable in the context of typical vehicle certifications.