Fork - In 2003, all EXC models will be outfitted with White Power USD 48 mm forks. In contrast to the 43 mm of 2002, the new fork has now three bushes per fork tube, which ensures a better guidance of the inner tubes during compression travel. Both wipe and radial shaft seal, as well as the bearings, were obtained from new suppliers and, in combination with a new fork oil, ensure a markedly improved response.
KTM also improved chromium quality of the fork coating to prevent excessive “pumping up“ of the fork in use. The fork plates on the Enduro models were adapted to the new fork diameter.

Shock Absorber - The WP PDS shock absorber was modified considerably. A bigger compensating tank and a larger oil volume prevent premature fading. Changed flow cross-sections for the oil stream and new tuning setups provide better progression. This results in an improved response with a greater impact resistance.

Axle/Hub - All EXC models come with a new front-wheel axle enlarged from 20 to 26 mm for greater directional stability, stiffness and a more accurate turn-in ability. The front-wheel hub was also given a new design and its diameter increased from 36 to 52 mm. The rear-wheel hub was also reinforced from 48 to 64 mm.

Handlebar/Footrest - All 2-stroke EXC models come with a high quality conified Renthal handlebar, all 4-stroke EXC models with a 12mm higher Magura handlebar of identical design. All 2003 EXC models will be fitted with the broader footrests of the SX machines.

Clutch Hose - To prevent damage all models are fitted with flexible steel clutch hoses.

Tank/Spoiler - All EXC models boast a new tank with the “SX“ look. Also the shape of the tank shrouds is made uniform for both models. The advantage for the Enduro models is a more ergonomic tank/seat contour and thus a better sitting position. All tanks come in a basic orange, slightly transparent. The EXC tanks are equipped with new fuel cocks.

Speedometer - The Enduro models come with a highly functional digital speedometer with a control unit which, as an option, can be remote controlled at the end of the handlebar (trip master).

Plastic Components - The new series look for 2003 is taken from KTM’s winning 2002 GP Team. All models come with a newly designed front wheel fender for improved splash protection. A full-width radiator guard (on the 4-stroke racing KTM’s) provides for optimum air guidance and efficient cooling. A new, seamless seat cover creates an ideal surface.

Graphics Design/Colors - In 2003 the rear mudguard and the side paneling are orange, the shrouds, lamp mask, and the front mudguard is also orange. The seat is black. The KTM shroud logo was given a new design so as to cover the entire shroud. The frame and the hubs are power-coated in a gold hue, matching the color of the fork and the handlebar.

Improvements specific to the 200 EXC

Transmission - Considering the ever increasing engine performance of recent models, the new 125/200 6-gear transmission now comes with a new, wider and thus more load-resistant 2nd gear.

Gearshift Mechanism - A new aluminum gear selector drum having narrower shift grooves permits an even smoother shifting operation, especially in extreme-load situations (powershift). In addition, a new bearing roller of the gearshift fork helps minimize wear.

Crank gear/Piston - The 200cc models are given a new crankshaft for improved balancing and reduced inertia weight. The result is the reduction of vibrations and weight as well as a quicker throttle response.

Cylinder - A new molded silicone ring supersedes the paper seal to provide ideal sealing for the 200cc cylinder head. The combustion chamber in the cylinder head was given a new shape and the transfer ducts were modified in a new casting mold for optimum power yield.