KTM 200EXC 250EXC 300EXC comparison and review︱Cross Training Enduro

Decided on a two stroke but struggling to decide between a 200 EXC, 250 EXC or a 300 EXC? Welcome to our KTM 200EXC 250EXC 300EXC comparison and review! This summary of the KTM two strokes gives an idea of what to expect from each bike. None would be a mistake, but the KTM 200 EXC is great for tight gnarly trails, the 250 EXC is a great all round dirt bike while the 300 EXC has heaps of power for the very experienced rider, or anyone who wants to lug the engine like a four stroke and change gears less. We have done a list of known issues and common problems for various dirt bikes, now it's time to look at the Austrian pumpkins. Our KTM 200EXC 250EXC review includes a common criticism of KTM and Husqvarna is they bring out some of their innovations too soon and customers become their guinea pigs, resulting in a lot of recalls and ongoing problems. Or you can buy a Japanese bike which usually has barely changed the past 15 years but has far less known issues. Frankly I'm not sure how true this is, but at least it makes sense to know what the known issues are with any brand, and fix things before they become a problem. So let's start with product recalls from KTM and Husqvarna. These are the more serious problems with 200 EXC, 250 EXC or a 300 EXC because riders can get hurt. So the accountants and lawyers work out the potential cost of getting sued, versus the cost of actually fixing the mistakes. If it's cheaper to just fix the bike, they will issue a recall. On earlier models, you can see in certain models there were potential problems with fuel leaks, front forks seizing, front forks snapping, throttles locking open, or loss of braking. More recently there are still potential problems with fuel leaks and loss of braking, but also new issues with spokes, connecting rods and rear shocks on certain models. Remember these issues don't always affect every model, sometimes it might only be in certain batches produced that year. Check with your dealer for more information. There are a lot of recalls on their street bikes too but we'll leave that for someone else to cover. Next are all the issues not serious enough to issue a product recall. Each year KTM dealers receive a list of these which we can't access, but you'll occasionally see the issues pop on forums like this one:
"2016 KTM 125 SX and 150 SX models have been found to have cracks in engine cases due
to incorrect assembly, leading to transmission oil entering the combustion chamber and causing excessive exhaust smoking." So it comes down to scouring the forums, chatting with owners, and trying to sort out the truth from the alarming amount of bullshit on the internet.

Until the new design in 2017, the 200 EXC, 250 EXC and 300 EXC two stroke starter motors were widely seen as a very unreliable weak design that needed frequent maintenance. We've done a whole video about keeping these suckers working, just google this:
KTM starter motors 250EXC 300EXC common problems, maintenance & repairs Thankfully the new design seems to be working well. Apart from product recalls on certain 4CS forks, they were very widely criticised for being much worse than the earlier forks. I spoke with the suspension specialists at FFRC who tested them on their dyno chart and they said it looked as though the KTM suspension crew went to lunch and never finished the job properly. There are various fixes available, check out this video: 4CS forks tuning: Full Force Racing Components

A minor but persistent problem, the weak sidestand on the enduro models. In the quest for light weight most European bikes have weak sidestands but KTM are probably the worst. If it falls off just buy a decent aftermarket one.

A fairly rare issue was the weak idler gear on 2017 models, but it would be a much more common problem if riders used their kick starters a lot. Some riders were finding this was breaking even on their first ride. The best fix possible is to use a longer bolt and tap the thread to make room for this. Have fixed this for 2018 and also redesigned the case to provide more support.
https://thumpertalk.com/forums/topic/1253879-2017-2-stroke-idler-gear-snapped/

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