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200 EXC EU 2010
KTM 200 EXC EU 2010 User Manual
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SERVICE
S
CHEDULE
36
S20A:
every
20
operating
hours
S40A:
every
40
operating
hours/after
every
race
10.2
Important
mainte
nance
work
to
be
carried
out
by
an
authorized
KTM
workshop
(as
additional
order)
Competition
use
Hobby
use
S10A
S20
N
S30A
J1A
S10A
S20A
S40A
S80A
S20A
S40A
S60A
S80A
Perform
a
fork
service.
(EXC,
EXC
SIX
DAYS,
XC-W)
x
•
•
•
•
Perform
a
shock
absorber
service.
(EXC,
EXC
SIX
DAYS,
XC-W)
x
•
•
•
Conduct
a
minor
fork
service.
(XC)
x
•
•
Conduct
a
major
fork
service.
(XC)
x
•
Perform
a
shock
absorber
service.
(XC)
x
•
•
•
•
•
Grease
the
steering
head
bearing.
x
•
Change
the
foot
brake
cylinder
seals.
x
•
•
•
•
•
Change
the
glass
fiber
yarn
filling
of
the
main
silencer.
x
(
p.
81)
•
•
•
•
•
Change
the
hydraulic
clutch
fluid.
x
(
p.
84)
•
Change
the
front
brake
fluid.
•
Change
the
rear
brake
fluid.
•
Treat
electric
con-
tacts
with
contact
spray.
•
Check/set
the
car-
buretor
compo-
nents.
x
•
•
•
Check
the
intake
diaphragm.
x
•
•
•
•
•
Check
the
clutch
lining
discs.
x
•
•
•
•
•
Check
the
length
of
the
clutch
springs.
x
•
•
•
•
•
Check
the
cylinder
and
piston.
x
•
•
•
•
•
Check
the
seating
of
the
piston
pin.
x
•
•
•
•
•
37
39
Table of Contents
Table of Contents
4
Means of Representation
7
Important Information
8
View of Vehicle
10
View of the Vehicle from the Left Front (Example)
10
View of the Vehicle from the Right Rear (Example)
11
Location of Serial Numbers
12
Chassis Number
12
Type Label
12
Key Number (EXC, EXC SIX DAYS)
12
Engine Number
12
Fork Part Number
12
Shock Absorber Part Number
13
Controls
14
Clutch Lever
14
Hand Brake Lever
14
Throttle Grip
14
Short Circuit Button (EXC, EXC SIX DAYS)
14
Short Circuit Button (XC-W/XC)
15
Emergency off Switch (200 EXC AUS)
15
Emergency off Switch (250/300 EXC AUS)
15
Electric Starter Button (300 EXC EU, 300 EXC SIX DAYS, 250/300 XC-W, 250/300 XC)
15
Electric Starter Button (250/300 EXC AUS)
15
Light Switch (EXC, EXC SIX DAYS)
16
Light Switch (XC-W)
16
Horn Button (EXC, EXC SIX DAYS)
16
Turn Signal Switch (EXC, EXC SIX DAYS)
16
Overview of Indicator Lamps (EXC, EXC SIX DAYS)
16
Controls (All Exc/XC-W Models)
17
Speedometer
17
Speedometer Activation and Test
17
Tripmaster Switch
17
Setting Kilometers or Miles
17
Setting the Clock
18
Adjusting Speedometer Functions
18
Querying the Lap Time
19
Display Mode SPEED (Speed)
19
Display Mode SPEED/H (Service Hours)
19
Display Mode SPEED/CLK (Clock)
20
Display Mode SPEED/LAP (Lap Time)
20
Display Mode SPEED/ODO (Odometer)
20
Display Mode SPEED/TR1 (Trip Master 1)
20
Display Mode SPEED/TR2 (Trip Master 2)
21
Display Mode SPEED/A1 (Average Speed 1)
21
Display Mode SPEED/A2 (Average Speed 2)
21
Display Mode SPEED/S1 (Stop Watch 1)
22
Display Mode SPEED/S2 (Stop Watch 2)
22
Controls
24
Fuel Tap
24
Opening the Filler Cap
24
Closing the Filler Cap
24
Choke (EXC AUS, XC-W/XC)
24
Choke (EXC EU, EXC SIX DAYS)
25
Shift Lever
25
Kickstarter
25
Foot Brake Lever
26
Side Stand
26
Steering Lock (EXC, EXC SIX DAYS)
26
Locking the Steering (EXC, EXC SIX DAYS)
26
Unlocking the Steering (EXC, EXC SIX DAYS)
27
General Tips and Hints on Putting into Operation
28
Advice on First Use
28
Running in the Engine
29
Preparing the Vehicle for Difficult Operating Conditions
29
Preparations for Riding on Dry Sand
29
Preparations for Riding on Wet Sand
30
Preparations for Riding on Wet and Muddy Surfaces
31
Preparations for Riding at High Temperatures and Riding Slowly
32
Preparations for Riding at Low Temperatures and in Snow
32
Riding Instructions
33
Checks before Putting into Operation
33
Starting
33
Starting up
34
Shifting, Riding
34
Braking
34
Stopping, Parking
35
Refueling
35
Service Schedule
37
Important Maintenance Work to be Carried out by an Authorized KTM Workshop
37
Important Maintenance Work to be Carried out by an Authorized KTM Workshop (as Additional Order)
38
Important Checks and Maintenance Work to be Carried out by the Rider
39
Maintenance Work on Chassis and Engine
40
Jacking up the Motorcycle
40
Removing the Motorcycle from the Work Stand
40
Checking the Basic Chassis Setting with the Rider's Weight
40
Compression Damping of Shock Absorber
40
Adjusting the High-Speed Compression Damping of the Shock Absorber
40
Adjusting the Low-Speed Compression Damping of the Shock Absorber
41
Adjusting the Rebound Damping of the Shock Absorber
42
Measuring the Sag of the Unloaded Rear Wheel
43
Checking the Static Sag of the Shock Absorber
43
Checking the Riding Sag of the Shock Absorber
44
Adjusting the Spring Preload of the Shock Absorber
44
Adjusting the Riding Sag
45
Removing the Shock Absorber
45
Installing the Shock Absorber
46
Checking the Basic Setting of the Fork
46
Adjusting the Compression Damping of the Fork
46
Adjusting the Rebound Damping of the Fork
47
Adjusting the Spring Preload of the Fork (EXC, EXC SIX DAYS, XC-W)
48
Bleeding the Fork Legs
49
Cleaning the Dust Boots of the Fork Legs
49
Loosening the Fork Protection
49
Positioning the Fork Protection
49
Checking the Play of the Steering Head Bearing
50
Adjusting the Play of the Steering Head Bearing
50
Removing the Fork Legs
51
Installing the Fork Legs
52
Removing the Fork Protector
53
Installing the Fork Protector
53
Removing the Front Fender
53
Installing the Front Fender
53
Removing the Headlight Mask with the Headlight (EXC, EXC SIX DAYS)
54
Refitting the Headlight Mask with the Headlight (EXC, EXC SIX DAYS)
54
Removing the Start Number Plate (XC-W/XC)
54
Installing the Start Number Plate (XC-W/XC)
55
Handlebar Position
55
Adjusting the Handlebar Position
55
Checking the Play in the Throttle Cable
56
Adjusting the Play in the Throttle Cable
56
Checking the Chain for Dirt
56
Cleaning the Chain
56
Checking the Chain Tension
57
Checking the Rear Sprocket/Engine Sprocket for Wear
57
Checking Chain Wear
57
Adjusting the Chain Tension
58
Adjusting the Chain Guide
59
Checking the Brake Discs
60
Checking the Free Travel of the Hand Brake Lever
60
Adjusting the Basic Position of the Hand Brake Lever (XC-W/XC)
61
Adjusting Free Travel of Hand Brake Lever (EXC, EXC SIX DAYS)
61
Checking the Front Brake Fluid Level
61
Adding Front Brake Fluid
62
Checking the Front Brake Linings
62
Changing the Front Brake Linings
63
Checking the Free Travel of the Foot Brake Lever
64
Adjusting the Basic Position of the Foot Brake Lever
65
Checking the Rear Brake Fluid Level
65
Adding Rear Brake Fluid
66
Checking the Rear Brake Linings
66
Removing the Rear Brake Linings
67
Installing the Rear Brake Linings
67
Changing the Rear Brake Linings
68
Removing the Front Wheel
68
Installing the Front Wheel
69
Removing the Rear Wheel
70
Installing the Rear Wheel
70
Checking the Tire Condition
71
Checking the Tire Air Pressure
72
Checking the Spoke Tension
72
Engine Characteristic - Auxiliary Spring (All 250/300 Models)
73
Engine Characteristic - Adjusting the Auxiliary Spring (All 250/300 Models)
73
Removing the Battery
74
250 EXC AUS/XC-W/XC, All 300 Models)
74
Installing the Battery
74
Recharging the Battery (250 EXC AUS/XC-W/XC, All 300 Models)
74
Removing a Fuse (250 EXC AUS/XC-W/XC, All 300 Models)
75
Replacing the Fuse (250 EXC AUS/XC-W/XC, All 300 Models)
75
Checking the Headlight Setting (EXC, EXC SIX DAYS)
76
Adjusting the Headlight Range (EXC, EXC SIX DAYS)
76
Removing the Seat
76
Mounting the Seat
77
Removing the Fuel Tank
77
Installing the Fuel Tank
78
Cooling System
78
Checking the Antifreeze and Coolant Level
79
Checking the Coolant Level
79
Draining the Coolant
80
Refilling with Coolant
81
Removing the Main Silencer
82
Installing the Main Silencer
82
Glass Fiber Yarn Filling of Main Silencer
82
Removing the Glass Fiber Yarn Filling of the Main Silencer
82
Installing the Glass Fiber Yarn Filling of the Main Silencer
83
Changing the Glass Fiber Yarn Filling of the Main Silencer
83
Removing the Air Filter Box Lid
83
Installing the Air Filter Box Lid
83
Removing the Air Filter
83
Installing the Air Filter
84
Cleaning the Air Filter
84
Adjusting the Basic Position of the Clutch Lever
85
Checking the Fluid Level of the Hydraulic Clutch
85
Changing the Hydraulic Clutch Fluid
86
Checking the Basic Position of the Shift Lever
87
Adjusting the Basic Position of the Shift Lever
87
Carburetor
87
Carburetor - Adjusting the Idle Speed
88
Emptying the Carburetor Float Chamber
89
Checking the Gear Oil Level
90
Changing the Gear Oil
90
Draining the Gear Oil
91
Refilling with Gear Oil
91
Adding Gear Oil
92
Troubleshooting
93
Cleaning
95
Cleaning the Motorcycle
95
Storage
96
Putting into Operation after Storage
96
Technical Data - Engine
97
125 Exc Eu, 125 Exc Six Days Eu
97
150 XC Usa
97
All 200 Models
98
All 250 Models
98
All 300 Models
99
Capacity - Gear Oil
100
Capacity - Coolant
100
Technical Data - Engine Tightening Torques
101
All 125/150/200 Models
101
All 250/300 Models
101
Technical Data - Carburetor
103
125 Exc Eu, 125 Exc Six Days Eu
103
150 XC Usa
103
200 Exc Eu
103
200 Exc aus
103
200 XC-W Usa
104
250 Exc Eu, 250 Exc Six Days Eu
104
250 Exc aus
104
250 XC Eu/Usa
104
250 XC-W Usa
105
300 Exc Eu, 300 Exc Six Days Eu
105
300 Exc aus
105
300 XC Eu/Usa, 300 XC-W Usa
105
Carburetor Configuration (125 EXC EU, 125 EXC SIX DAYS EU)
106
Carburetor Configuration (150 XC USA)
107
Carburetor Configuration (All 200 Models)
108
Carburetor Configuration (250 EXC EU, 250 EXC SIX DAYS EU, 250 EXC AUS, 250 XC-W USA)
109
Carburetor Configuration (250 XC EU/USA)
110
Carburetor Configuration (All 300 Models)
111
General Carburetor Configuration
112
Technical Data - Chassis
113
Lighting Equipment
114
Tires
114
Capacity - Fuel
114
Technical Data - Fork
115
All 125/200 Models
115
150 XC Usa
115
All 250/300 EXC/XC-W Models
116
250/300 XC
116
Technical Data - Shock Absorber
117
All 125/200 Models
117
150 XC Usa
117
All 250/300 EXC/XC-W Models
118
250/300 XC
118
Technical Data - Tightening Torques for Chassis
120
Wiring Diagram
123
Wiring Diagram (125 EXC EU, 125 EXC SIX DAYS EU, 200 EXC EU, 200 EXC AUS, 250 EXC EU, 250 EXC SIX DAYS EU)
123
Wiring Diagram (250/300 EXC AUS, 300 EXC EU, 300 EXC SIX DAYS EU)
126
Wiring Diagram (150 XC USA, 200 XC-W USA)
128
Wiring Diagram (250/300 XC-W, 250/300 XC)
130
Substances
132
Auxiliary Substances
134
Standards
136
Index
137
Other manuals for KTM 200 EXC EU 2010
Setup Instructions
15 pages
4
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KTM 200 EXC EU 2010 Specifications
General
Brand
KTM
Model
200 EXC EU 2010
Category
Motorcycle
Language
English
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