KTM 200 EXC SIX DAYS 1999-2010 Factory Service Repair Manual
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🏷️ Basic Information Identification Make: KTM Model: 200 EXC SIX DAYS Model Variant: 200 EXC SIX DAYS Body Style: Dual-Sport / Enduro Motorcycle Codes Vin Code Engine Type: Typically 'F' for Four-Stroke Vin Code Model Designator: Varies by specific EXC generation, but often indicates Off-Road/Enduro 👋 Introduction Market Position Segment: High-performance off-road/enduro motorcycle Target Audience: Enthusiast riders, mechanics, competitive racers Competitive Analysis Competitors: Husqvarna TE250, Yamaha WR250, Honda CRF250X, Suzuki RM-Z250, Kawasaki KX250 Key Features Engine Configuration: Compact and powerful two-stroke engine Suspension Design: Advanced WP suspension components Handling: Agile and precise handling characteristics Six Days Edition Specialties: Often includes specific graphics, upgraded components, and sometimes different tuning from standard models 📋 Manual Details Coverage Areas Manual Type: Factory Service Repair Manual Language: English Format: PDF Download Applicable Years: 1999, 2000, 2001, 2002, 2003, 2004, 2005, 2006, 2007, 2008, 2009, 2010 Page Count Estimated Page Count: 300-400 pages (typical for this type of manual) 📖 Manual Coverage Systems Covered Engine Mechanical: Complete overhaul, disassembly, assembly, tuning, specifications Fuel System: Carburetor tuning and rebuilding (e.g., Mikuni VM series), fuel lines, tank maintenance Ignition System: CDI unit, spark plug selection, troubleshooting Cooling System: Radiator, coolant specifications, pump maintenance, bleeding procedures Exhaust System: Muffler, header pipe, packing replacement, torque specifications Transmission: Clutch operation, gearbox disassembly/assembly, oil specifications, shift mechanism Suspension Front: Fork servicing, oil level and type, seal replacement, valving, spring rates, adjustments Suspension Rear: Monoshock servicing, linkage lubrication, shock absorber adjustments, seal replacement Brakes Front: Caliper maintenance, piston seals, brake pad replacement, fluid type, bleeding, rotor specifications Brakes Rear: Caliper maintenance, piston seals, brake pad replacement, fluid type, bleeding, rotor specifications Electrical System: Wiring diagrams, battery maintenance, stator, regulator/rectifier, lighting, switches Chassis Frame: Frame inspection, headstock bearing maintenance, swingarm lubrication, bolt torque specifications Wheels Tires: Spoke tensioning, wheel bearing replacement, tire pressure recommendations, rim specifications Bodywork: Fairing removal/installation, seat, plastics Procedures Included Routine Maintenance: Oil changes, filter replacements, chain adjustment, spark plug inspection, air filter cleaning Troubleshooting: Diagnostic flowcharts for common issues (e.g., starting problems, overheating) Engine Rebuild: Piston, rings, cylinder head, crankshaft, valve timing, compression testing Suspension Rebuild: Fork seal replacement, shock absorber rebuild procedures Brake System Service: Bleeding, pad replacement, caliper overhaul Electrical Diagnostics: Fault finding using wiring diagrams, component testing Carburetor Tuning: Jetting recommendations for various conditions, idle speed adjustment Technical Depth Depth Of Information: Comprehensive (from basic maintenance to full engine and component rebuilds) Diagnostic Capability: Advanced diagnostics and troubleshooting guidance Service Data: Includes detailed torque specifications, clearances, and fluid capacities 📊 Manual Specifications File Format File Type: PDF (Portable Document Format) Searchable Text: Likely (as it's a factory manual) Print Quality Scalability: High (printable at various sizes without quality loss) Binding Type Digital Format: N/A (Digital Download) Paper Type Digital Format: N/A (Digital Download) ⚙️ Engine Specifications Primary Engine Engine Type: Single-cylinder, 2-stroke, liquid-cooled Displacement: 193 cc (approximately) Bore X Stroke: Typically around 62.5 mm x 65 mm (exact figures can vary slightly by year) Compression Ratio: Typically around 12.5:1 to 13.5:1 (check specific year manual) Valve Train: Reed valve induction, exhaust control (e.g., KTM's Power-Jet system or similar) Performance Horsepower Approximate: Around 30-35 HP (at crankshaft, varies by year and tuning) Torque Approximate: Around 20-22 lb-ft (at crankshaft, varies by year and tuning) Fuel System Carburetor Type: Mikuni VM series (e.g., VM38 or similar) or Keihin PWK Fuel Type: Unleaded gasoline (91+ octane recommended) Oil Mixture: 2-stroke oil pre-mix at recommended ratio (e.g., 50:1 or 40:1 depending on oil and usage) Lubrication Engine Oil Type: SAE 10W-50 2-stroke synthetic oil for premix 🔧 Transmission Standard Transmission Type: 6-speed constant mesh Clutch Type: Wet multi-disc clutch, hydraulically operated Features Gear Ratios: Specific gear ratios are detailed in the manual, crucial for off-road performance tuning Final Drive: O-ring chain (e.g., 520 pitch), with adjustable gearing ratios Transmission Oil Type: SAE 10W-40 or SAE 80W-90 gear oil (specific grade detailed in manual) 📐 Dimensions Exterior Wheelbase: Approximately 1470 mm (57.9 inches) (can vary slightly by year) Seat Height: Approximately 950 mm (37.4 inches) (unladen) Weights Dry Weight: Around 100-105 kg (220-231 lbs) (without fuel) Fuel Tank Capacity: Approximately 8.5-10 liters (2.2-2.6 gallons) 🛡️ Safety Features Ratings Safety Certification: CE certification (for European markets), potentially EPA compliance for US models Active Features Braking System: Hydraulic disc brakes front and rear Lighting: Headlight, taillight, brake light, turn signals (depending on street legality of specific model) Passive Features Frame Construction: Chromium-molybdenum steel central double-cradle frame 💡 Technology Features Infotainment Instrument Cluster: Digital or analog instrument cluster displaying speed, RPM, odometer, trip meter, and indicator lights. Driver Assistance ABS: ABS was not standard or widely available on off-road models of this era; check specific model configuration. Connectivity Bluetooth Connectivity: N/A Engine Management Ignition Control: CDI ignition system with engine management for optimal combustion and power delivery. 🔧 Maintenance Service Intervals Engine Oil Change:...
Two-stroke carburetors can be sensitive to altitude and temperature changes, requiring periodic adjustment.
Power Valve Maintenance:
The exhaust power valve mechanism can accumulate carbon deposits, requiring cleaning to maintain optimal performance.
📚 Vehicle History
Brand Heritage
Ktm Legacy:
KTM has a strong heritage in off-road racing, particularly in motocross and enduro
Model Evolution
Exc Series:
The EXC series has been KTM's flagship off-road model line for decades, evolving with engine technology and chassis designs.
200Cc Displacement:
The 200cc variant offered a balance of manageable power and agility, often favored for technical terrain.
Six Days Editions:
These models celebrate KTM's participation and success in the International Six Days Enduro (ISDE), often featuring special editions with enhanced components.
Production
Manufacturing Location:
Austria (KTM Motorcycles AG)
🏆 Awards & Recognition
Recognitions
Editorial Reviews:
KTM EXC models consistently receive positive reviews for their performance, handling, and durability in off-road conditions.
Ratings
Off Road Competitions:
KTM is a dominant force in various off-road racing disciplines, including enduro.
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