20 Most Recent 2002 KTM EXC 200 Questions & Answers

Thanks for contacting FixYa with your KTM inquiry.
50 kilometers is equivalent to 31 miles. The tank capacity is 2.9 Gallons indicating you are obtaining a very sub-marginal 10mpg approximately.
A couple things to check would be:

• Leaks/cracks in the fuel line.
• Access fuel is going somewhere - is it making OIL/Going out the pipe? Seals or Jets!
• Excessive smoke out the pipe.
• Pipe color coming out of the cylinder head (Cherry Red = over fueling)
• Spark plug color - should be a nice cocoa brown is jetting is correct.

More than likely you have either a stuck float or a jetting problem. Both are very easy to fix. Tap the float bowl with a back side of a screw driver and see if it frees up. Test ride!
For jetting, you can raise the clip on the needle a couple of notches so the needle lowers and this should help conserve fuel in the middle RPM range.
The pilot jet and tower will gobble up fuel like crazy at low RPM's if they are to large a diameter. Refer to your manual and check the stock size for jetting and start with that. Elevation and temp has some effect on jetting as well. Just sounds like more than likely your needle and pilot jet are over fueling the engine.
Hope this gives you a few ideas. Let us know if we can be of further service,
Kind regards,
TF

This is normal for a 2 stroke and not a problem at all. It's just a build up of 2 stroke oil that acumulates i the the packing in the muffler.
Nothing to worry about, and no solution to fix it really. You can re pack your muffler with clean packing, and try running a little less 2 stroke oil in your mix. I would recomend using a synthetic 2 stroke oil, with a mixture of 50:1 this would prevent some of the mess from happening.

Im gettin a KTM 2 stroke soon. Its kinda of old (1996). But it seems it was aken care of previously. What Can i do interms of maintenance? except for changing the oil... and also whta is jetting ? i seem to here a lot in these forums . And how should i know the best fuel / oil mix for my bike ? how important is it in terms of accuracy of the mixture? P.S im a total newbie in bike engineseveryone seems to think piston lasts for 30+ hrs. however pretty much alot of people that ride the 2 stroke decent enough get engine lock-ups...i wonder why ? i change my piston every 12-15 hours or when the play exceeds 0.08mm. i can go in very technical detail why but i don't feel like it.it's kinda long and boring in any case it has to do with the way the cylinder/piston wears (same for 2 or 4 stroke). Plug when it looks old...change it.it's not liek it's a very expensive part anyways. airfilter...clean it , with detergent/soap some people use airfilter cleaner , i find soap and warm water works well then i hang it to dry and after it's dry i oil it up and stick it back in the bike. frequent maintanance on any engine is important , i have been riding 125's for many years and i have yet to expierence engine failure...ofcourse i have been stopped by a broken chain...or a flat tire. but i haven't had any engine related failures in the past 7+ years.due to piston related lock-ups(except one time when one of the hoseclamps on the water hose came off and the engine over heated)that's one incident out of 100's of races i have ran...not that bad eh ? unlike many of the younger generation seem to believe , a 2 stroke is not any less reliable then a 4 stroker , not even a 125 is less reliable , and no you don't have to keep it at full rpm all the time either , it won't blow if it's setup right and maintained regularly. take care of your baby and she will take care of you, that's all there's to it. ,,,

Thank you for contacting FixYa with your inquiry.
This is not to bad of a parts replacement. The seal on the gear selector gets a lot of down thrust and has a tendency to wear to a slightly oval shape and leak.
The easiest way to fix is remove the gear selector lever (Mark the position with an awl or nail). Then remove the side case. Ease it off so you don't damage the gasket. You should now be able to pry the old one out with a screw driver. Lightly coat the new one with Loctite bearing mount and gently tap back into place. Replace the gasket if you tore or damaged the old side case gasket.
This should be a simple and inexpensive fix.
If you need more assistance let us know,
Best regards,
TF

The fork seals need replaced you have yo really know what you are doing to do this job yourself

Hi, i presume from your thread you have removed the bolt securing the damper to the leg at the axle end, and you are having a problem removing the stancion from the leg, normaly you will have to remove the fork dust seal from the top of the fork leg, you will then expose the main fork seal which will be secured inside the fork leg by a clip,you will need to remove this, as the bushing inside the fork. Is secured to the stancion underneath the fork seal the only way to separate this, once the seal clip is removed, fasten the lower leg in a vice, warning fasten in the axle area and not the tube area to save damage, once secure push the fork tube all the way to the bottom, then pull up sharpley, repaeting this action will give a hammer effect from the inside of the fork, when reasembling before fixing the damper unit replace the fork stanchion, bushing, washer and seal, holding the tube. Upermost will reduce the risk of damage while replacing the seal in the moving area

yes it is starving for fuel. please put in a larger jet. you may want to go to the 3erd next higher one. remember you can add more air from the mixture screw.

try mixing 50:1 with synthetic it will not hurt rings 32:1 is pretty thick!!!on all two strokes i mix 50 to one never have had problem!Best of Luck to You!!!

G'day jarm.
Hope i'm not to late to respond.
First of all push the valve or control flap as ktm calls it,upwards through the exaust port,turn the pin a quarter of a turn,you can do this with a metric 5x40 bolt,then......SHAAABOOOMM.that valve should come straight.Installation???.Well i guess you can see how it works now,basically the reverse of removal,Just make sure to lube the pin,insert until it engages the flap,then rotate it a quarter(1/4)of a turn.The flat section on the pin must face out toward the exaust port.
Good luck and hope i could help
J STRONGARMS...hehee ..ha haaa!
regards..Silleydog.

It takes a hydraulic press to separate a crankshaft. Beyond that, you must have twin dial guages when reassembling the crank so that the two halves are set in correct alighnment. NOT a job for amatures.

That would be like riding a fixed wheel bike.Think about how you will stop and start. Only hydraulic fluid will leak. Bad idea!

Question edited for clarity. That sounds like it is just a bad connection somewhere or possibly a bad switch. Remove the battery leads and clean the lead contacts and battery posts with a wire brush. Smear with Vaseline and reconnect. Remove the starter leads and do the same. Then it could be the Starter Relay https://www.google.com/search?q=ktm+450+sx-f+starter+relay+location Or Starter Button https://www.google.com/search?q=ktm+450+sx-f+starter+button+replacement ..

personnaly I would replace cylinder with new OEM

All dirt bikes have a VIN. It is on the steering neck. https://www.google.com/search?q=vin+on+my+ktm+300 ..

Have you checked battery connections. Run switch in the correct position? Checked spark plug for debris? Just thinking out loud..

Drain oil. Use degreaser to clean area. Use JB Weld & allow to set up properly before adding oil.

If you’ve found this helpful, please click the green “helpful” icon. If you have 20 seconds please leave a few words as a review or recommendation! Also, follow me for more answers to everyday issues, I’m all for saving you money and making the most of your time! Thanks and have a great day!

Hi, try to see this link and looking for the manual that you need. https://www.pdfmotomanual.com/manuales/ktm/eng I hope to give you an help. Luca

my ­b­est ­fr­i­e­n­d's s­ist­er-­i­n-­l­Aw ­m­A­k­es $74 ­ev­ery ­h­our ­o­n t­h­e ­c­o­m­put­er. S­h­e ­h­As ­b­e­e­n u­n­e­m­p­l­oy­e­d ­f­or t­e­n ­m­o­nt­hs ­but ­l­Ast ­m­o­nt­h ­h­er ­p­Ay­m­e­nt w­As $16505 just w­or­k­i­n­g ­o­n t­h­e ­c­o­m­put­er ­f­or ­A ­f­ew ­h­ours. ­g­o t­o t­h­is w­e­b s­it­e ­A­n­d r­e­A­d ­m­or­e ­g­o t­o t­h­is s­it­e ­h­o­m­e t­A­b ­f­or ­m­or­e ­d­et­A­i­l ... www.online-3.com

Hi, most likely your cdi unit or ignition coil needs replacing.

took me a min or two of WTF-ing to see pic and realize you meant a 2-stroke motorcycle..