Vehicle Segment:
Off-road, Enduro, Motocross
Target Audience:
Enthusiast riders, amateur racers, and those seeking a capable lightweight off-road machine.
Key Competitors:
Yamaha WR200, Honda CR250 (though larger displacement), Suzuki RM-Z250, Kawasaki KX250 (2-stroke variants).
Handling:
Renowned for agile and precise handling, characteristic of KTM's off-road prowess.
Performance Focus:
Emphasis on lightweight construction and a potent 2-stroke engine for spirited off-road riding.
Durability:
Built with KTM's reputation for robust construction suitable for demanding off-road conditions.
Vehicle Models Covered:
KTM 200 EXC (1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010)
Estimated Page Count:
500+
Manual Type:
Service Repair Workshop Manual
Engine:
Complete engine overhaul, top-end and bottom-end rebuilds, piston, rings, cylinder, crankshaft, connecting rod, bearings, seals, gaskets, cooling system (radiator, fan, hoses, coolant).
Fuel System:
Carburetor (Keihin PWK series) disassembly, cleaning, adjustment, jetting, fuel pump (if applicable), fuel lines, fuel tank.
Transmission:
Gearbox disassembly, inspection, and reassembly; clutch operation, service, and replacement; gear shift mechanism.
Electrical System:
Ignition system (CDI, spark plug, coil), lighting system, wiring diagrams, battery, stator, regulator/rectifier, starter motor (if electric start equipped).
Suspension:
Front forks (WP USD) overhaul, seal replacement, oil level and type specification, damping adjustments. Rear shock absorber service, spring preload adjustment, rebound damping adjustment.
Brakes:
Hydraulic disc brakes (front and rear), caliper service, pad replacement, brake fluid type and bleeding procedures, master cylinder overhaul.
Chassis And Frame:
Frame inspection, swingarm removal and service, linkage systems (if applicable), bearings, bushings.
Bodywork And Controls:
Seat removal, plastics, handlebars, controls (throttle, clutch lever), footpegs, exhaust system removal and installation.
Maintenance:
Routine service intervals, oil changes, filter replacements (air, oil if applicable), chain maintenance, brake checks, tire pressure, spark plug replacement, decarbonization.
Troubleshooting:
Diagnostic guides for common running problems, starting issues, electrical faults, suspension noises, brake performance.
Repair:
Step-by-step instructions for component removal, installation, and repair for all major systems.
Diagnostics:
Explains diagnostic procedures for identifying faults using visual inspection, sound analysis, and basic measurement tools.
Level Of Detail:
Comprehensive, suitable for DIY enthusiasts and professional mechanics. Covers everything from basic maintenance to complete engine and transmission rebuilds.
Engine Type:
2-stroke, single-cylinder, liquid-cooled
Displacement:
193 cc (approximately, varies slightly by year)
Bore X Stroke:
62.5 mm x 65 mm (typical for this era)
Cooling System:
Liquid-cooled with fan assist
Ignition System:
Digital CDI (Capacitor Discharge Ignition)
Lubrication:
Pre-mix or automatic oil injection (depending on specific sub-model or year)
Horsepower Estimated:
35-40 hp (estimated, actual figures vary)
Torque Estimated:
25-30 Nm (estimated, actual figures vary)
Carburetor Type:
Keihin PWK (e.g., PWK 35)
Fuel Type:
Unleaded gasoline (minimum 95 RON recommended)
Fuel Mixture Ratio:
Typically 1:40 or 1:50 with a quality 2-stroke oil, consult manual for precise ratio.
Transmission Type:
6-speed constant mesh
Clutch Type:
Wet multi-plate clutch, hydraulically operated
Gear Ratios:
Specific gear ratios available within the manual for each gear.
Transmission Oil Type:
API GL-4 or GL-5 gear oil (e.g., Motul Gear 300 75W-90 or similar, consult manual for exact specification).
Transmission Oil Capacity:
Approximately 0.7-0.8 Liters (consult manual for exact capacity and level check procedure).
Safety Certification:
Not applicable for off-road use in the same way as street-legal vehicles; designed for off-road competition and recreational use.
Braking System:
Hydraulic disc brakes front and rear for effective stopping power.
Suspension Control:
Adjustable suspension components allow tuning for terrain and rider preference, aiding stability.
Frame Construction:
Robust steel frame designed for off-road abuse and rider protection.
Handguards:
Standard handguards to protect levers and rider's hands from roost and impacts.
Oil Change Interval:
Every 10-15 hours of riding or annually, whichever comes first (for transmission oil).
Air Filter Cleaning:
After every 5-10 hours of riding, or more frequently in dusty conditions.
Spark Plug Check Replace:
Check every 10-20 hours, replace as needed. Consult manual for recommended plug type and gap.
Top End Rebuild Interval:
Typically 50-100 hours depending on riding style and maintenance; manual provides detailed guidance.
Engine Oil Type:
High-quality 2-stroke premix oil (e.g., Motorex, Castrol, Motul) at specified ratio (1:40 to 1:50).
Cooling System Coolant:
Ethylene glycol based coolant, 50% mixture with distilled water. Consult manual for specific type and capacity.
Brake Fluid Type:
DOT 4 hydraulic brake fluid.
Power Valve Sticking:
Common issue on 2-strokes; requires regular cleaning and lubrication of the power valve mechanism.
Clutch Wear:
Clutch plates can wear over time, especially with aggressive riding; regular inspection and adjustment are necessary.
Carburetor Tuning:
May require tuning based on altitude, temperature, and modifications; jetting charts in the manual are crucial.
Suspension Seals:
Fork seal leaks can occur, requiring periodic replacement. Manual details proper seal installation.
