Question about 2003 KTM EXC 200

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I got a badly damaged cylinder on my 2003 KTM 200 EXC. OEM replacement is around $900. No luck on ebay. Anyone know where I can find one cheaper? -thanks

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Langcourt, ltd repairs and plates cylinders. They should have a web site.

Posted on Nov 04, 2010

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Posted on Jan 02, 2017

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Hi, Amy for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $0 you can download another one.
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My 2000 ktm 200 will not start


Hi, Aw98628 and the usual suspects are:
1. Fuel tank empty.
2. The fuel tank has old dead gas.
3. Fuel tank bottom contaminated with ethanol sludge, dirt, water, rust, etc.
4. Fuel supply valve/petcock turned off.
5. Fouled spark plugs.
6. Engine flooded as a result of overuse of the enrichner.
7. Vacuum hose to the fuel supply valve/petcock disconnected, broken, cracked, or pinched.
8. Fuel valve/petcock or filter clogged.
9. Fuel line to carburetor or throttle body pinched, kinked or blocked.
10. Carburetor float stuck.
11. Fuel injectors clogged.
12. A severely discharged or damaged battery, you need 12.5 volts or better and be able to pass a load test if necessary.
13. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
14. Loose or corroded wire connection at the coil or plug between ignition sensor and ECM module.
15. Spark plug cables in bad condition and shorting check for spark leakage in the dark, cable connections loose, or connected to the wrong cylinders.
16. Ignition timing incorrect due to a faulty ignition coil, ignition module or MAP, CMP, CKP, O2, TPS, ETP, IAC sensors.
17. Faulty neutral, clutch lever, or kickstand safety switch.
18. Faulty fuel pump or fuse or relay.
19. A stuck bent or burnt valve.
20. Tilt sensor needs a reset.
21. Security system not disarming alarm needs a reset.
22. Check for engine trouble codes.
For more information about your issue and valuable "FREE" downloads that you will need please click on the blue links below. Good luck and have a wonderful day.
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Hi, Anonymous for this scenario you will need your service, parts fiche, and owners manual if you can't find the best tool you ever bought for your Honda, despair not, for a mere zero $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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1 Answer

I have a ktm EXC 525 2004 and it will backfire when i trying to rev it, i can start the engine and it runs rough at idle then when i try to rev the engine the it backfires and runs really rough as the rev...


Hi, Nicholas and the usual suspects are:
1. Severely discharged or a damaged battery, should have 12.5 volts or better and be able to pass a "LOAD" test "WARNING" you can have 12.5 volts or better but little or zero amps and the battery must be replaced.
2. Check battery terminals for damage or corrosion, check the battery cables at "BOTH" ends for loose, corroded, or broken connectors, "INSIDE" and outside the cable harness, perform connector wiggle test and check cables with an ohmmeter if necessary.
3. Faulty main circuit breaker and or connections.
4. Faulty ignition coil and or connections.
5. Faulty spark plug, oil or gas fouled, wrong heat range or service type, wrong gap, loose in the cylinder head, broken electrode or insulator.
6. Faulty spark plug cables, leaking or broken, internal damage check for spark leakage in the dark.
7. Faulty ignition module, switch, CKP, MAP, CMP, sensor and or any connector in the ignition circuit could have corroded, loose, or broken pins/sockets
8. Burnt exhaust valve or air leak in the exhaust system.
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1 Answer

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Hi, Aw077958 for this scenario you will need your service, parts fiche, and owners manual if you can't find the best tool you ever bought for your KTM, despair not, for a mere zero $0 you can download another one. For more information about your issue and valuable "FREE" downloads that you will need for viewing or printing please click on the blue links below. Good luck and have a wonderful day.
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2003 KTM EXC 525 Racing how to replace the clutch plates


Hi, Sandman96130 for this scenario you will need your service manual, parts fiche, and owners manual if you can't find the best tool you ever bought for your Ktm, despair not, for a mere zero $0 you can download another one.
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I have lost the torque on my ktm exc 200 and its rpm is very high what could it be


Sounds like the clutch has gone out. Pick up a manual on this bike and see if it can be adjusted. I don't think it can though. You can look to spend around $150 on parts plus labor. Hope this helps. Good luck.

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