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KTM
Motorcycle
200 EXC
KTM 200 EXC User Manual
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1
3
Table of Contents
Default Chapter
4
Table of Contents
4
1 Means of Representation
7
Symbols Used
7
Formats Used
7
2 Safety Advice
8
Use Definition - Intended Use
8
Degrees of Risk and Symbols
8
Tampering Warning
8
Safe Operation
9
Protective Clothing
9
Work Rules
9
Environment
9
Owner's Manual
9
3 Important Notes
10
Guarantee, Warranty
10
Operating and Auxiliary Substances
10
Spare Parts, Accessories
10
Service
10
Figures
10
Customer Service
10
4 View of Vehicle
11
View of Vehicle, Front Left (Example)
11
View of Vehicle, Rear Right (Example)
12
5 Serial Numbers
13
Chassis Number
13
Type Label
13
Key Number (All EXC Models)
13
Engine Number
13
Fork Part Number
13
Shock Absorber Part Number
14
6 Controls
15
Clutch Lever
15
Hand Brake Lever
15
Throttle Grip
15
Kill Switch (All EXC Models)
15
Kill Switch (All XC-W Models)
16
Horn Button (All EXC Models)
16
Light Switch (All EXC Models)
16
Light Switch (All XC-W Models)
16
Turn Signal Switch (All EXC Models)
16
Emergency off Switch (EXC AU)
17
Electric Starter Button (All 200/250/300 EU/US Models, 300 EXC BR)
17
Electric Starter Button (EXC AU)
17
Overview of Indicator Lamps (All EXC Models)
17
Overview of Indicator Lamps (All XC-W Models)
17
Opening the Filler Cap
18
Closing the Filler Cap
18
Fuel Tap
19
Choke
19
Shift Lever
19
Kick Starter
20
Foot Brake Lever
20
Side Stand
20
Steering Lock (All EXC Models)
20
Locking the Steering (All EXC Models)
21
Unlocking the Steering (All EXC Models)
21
7 Speedometer
22
Speedometer Overview
22
Activation and Test
22
Setting Kilometers or Miles
22
Setting the Speedometer Functions
23
Setting the Clock
23
Viewing the Lap Time
23
Display Mode SPEED (Speed)
24
Display Mode SPEED/H (Service Hours)
24
Setup Menu
25
Setting the Unit of Measurement
25
Display Mode SPEED/CLK (Time)
26
Setting the Clock
26
Display Mode SPEED/LAP (Lap Time)
26
Viewing the Lap Time
27
Display Mode SPEED/ODO (Odometer)
27
Display Mode SPEED/TR1 (Trip Master 1)
27
Display Mode SPEED/TR2 (Trip Master 2)
28
Setting TR2 (Trip Master 2)
28
Display Mode SPEED/A1 (Average Speed 1)
28
Display Mode SPEED/A2 (Average Speed 2)
29
Display Mode SPEED/S1 (Stop Watch 1)
29
Display Mode SPEED/S2 (Stop Watch 2)
29
Table of Functions
30
Table of Conditions and Menu Activation
31
8 Preparing for Use
32
Advice on First Use
32
Running in the Engine
33
Preparing the Vehicle for Difficult Riding Conditions
33
Preparations for Riding on Dry Sand
34
Preparations for Riding on Wet Sand
34
Preparations for Riding on Wet and Muddy Surfaces
35
Preparations for Riding at High Temperatures and Low Speeds
35
Preparing for Riding at Low Temperatures or in Snow
36
9 Riding Instructions
37
Checks and Maintenance Work When Preparing for Use
37
Starting
37
Start off
38
Shifting, Riding
38
Braking
38
Stopping, Parking
39
Transport
39
Refueling
40
10 Service Schedule
41
Service Work (as Additional Order)
42
11 Tuning the Chassis
43
Checking the Basic Chassis Setting with the Rider's Weight
43
Compression Damping of Shock Absorber
43
Adjusting the Low-Speed Compression Damping of the Shock Absorber
43
Adjusting the High-Speed Compression Damping of the Shock Absorber
44
Adjusting the Rebound Damping of the Shock Absorber
44
Measuring the Sag of the Unloaded Rear Wheel
45
Checking the Static Sag of the Shock Absorber
45
Checking the Riding Sag of the Shock Absorber
46
Adjusting the Spring Preload of the Shock Absorber
46
Adjusting the Riding Sag
47
Checking the Basic Setting of the Fork
47
Adjusting the Compression Damping of the Fork
48
Adjusting the Rebound Damping of the Fork
49
Adjusting the Spring Preload of the Fork (EXC, XC-W)
50
Handlebar Position
51
Adjusting the Handlebar Position
52
12 Service Work on the Chassis
54
Raising the Motorcycle with the Lift Stand
54
Removing the Motorcycle from the Lift Stand
54
Bleeding the Fork Legs
54
Cleaning the Dust Boots of the Fork Legs
55
Removing the Fork Protector
55
Installing the Fork Protector
56
Removing the Fork Legs
56
Installing the Fork Legs
57
Removing the Lower Triple Clamp (200 XC-W US, 250 XC-W US, 300 EXC BR, 300 XC-W US)
58
Removing the Lower Triple Clamp (EXC EU, EXC Six Days, EXC EU/AU, Six Days)
59
Installing the Lower Triple Clamp
59
(200 XC-W Us, 250 XC-W Us, 300 Exc Br, 300 XC-W Us)
59
Installing the Lower Triple Clamp (EXC EU, EXC Six Days, EXC EU/AU, Six Days)
61
Checking the Play of the Steering Head Bearing
64
Adjusting the Play of the Steering Head Bearing
65
Greasing the Steering Head Bearing
66
Removing the Front Fender
66
Installing the Front Fender
67
Removing the Shock Absorber
67
Installing the Shock Absorber
67
Removing the Seat
68
Mounting the Seat
68
Removing the Air Filter Box Lid
69
Installing the Air Filter Box Lid
69
Removing the Air Filter
69
Installing the Air Filter
70
Cleaning the Air Filter and Air Filter Box
70
Sealing the Air Filter Box
71
Removing the Main Silencer
71
Installing the Main Silencer
71
Changing the Glass Fiber Yarn Filling of the Main Silencer
71
Removing the Fuel Tank
72
Installing the Fuel Tank
73
Checking the Chain for Dirt
74
Cleaning the Chain
74
Checking the Chain Tension
74
Adjusting the Chain Tension
75
Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide
76
Checking the Frame
77
Checking the Swingarm
78
Checking the Routing of the Throttle Cable
78
Checking the Rubber Grip
79
Additionally Securing the Rubber Grip
79
Adjusting the Basic Position of the Clutch Lever
79
Checking/Correcting the Fluid Level of the Hydraulic Clutch
80
Changing the Hydraulic Clutch Fluid
80
Removing the Engine Guard
82
Installing the Engine Guard
82
13 Brake System
83
Checking the Free Travel of the Hand Brake Lever
83
Adjusting Free Travel of Hand Brake Lever (All EXC Models)
83
Adjusting the Basic Position of the Hand Brake Lever (All XC-W Models)
83
Checking the Brake Discs
84
Checking the Front Brake Fluid Level
84
Adding Front Brake Fluid
84
Checking the Front Brake Linings
85
Changing the Front Brake Linings
86
Checking the Free Travel of Foot Brake Lever
87
Adjusting the Basic Position of the Foot Brake Lever
87
Checking the Rear Brake Fluid Level
88
Adding Brake Fluid for the Rear Brake
89
Checking the Rear Brake Linings
89
Changing the Brake Linings of the Rear Brake
90
14 Wheels, Tires
92
Removing the Front Wheel
92
Installing the Front Wheel
92
Removing the Rear Wheel
93
Installing the Rear Wheel
94
Checking the Tire Condition
94
Checking the Tire Air Pressure
95
Checking the Spoke Tension
95
15 Electrical System
97
Removing the Battery (All 200/250/300 Models)
97
Installing the Battery (All 200/250/300 Models)
97
Recharging the Battery (All 200/250/300 Models)
98
Changing the Main Fuse (All 200/250/300 Models)
99
Removing the Headlight Mask with the Headlight
100
Refitting the Headlight Mask with the Headlight
100
Changing the Headlight Bulb
101
Changing the Turn Signal Bulb (All EXC Models)
101
Checking the Headlight Setting
102
Adjusting the Headlight Range
102
Changing the Speedometer Battery
103
16 Cooling System
104
Checking the Antifreeze and Coolant Level
104
Checking the Coolant Level
105
Draining the Coolant
105
Refilling with Coolant
106
17 Tuning the Engine
108
Checking the Play in the Throttle Cable
108
Adjusting the Play in the Throttle Cable
108
Carburetor - Idle
108
Carburetor - Adjusting the Idle Speed
109
Emptying the Carburetor Float Chamber
110
Checking the Basic Position of the Shift Lever
111
Adjusting the Basic Position of the Shift Lever
111
Engine Characteristic - Auxiliary Spring (All 250/300 Models)
111
Engine Characteristic - Setting the Auxiliary Spring (All 250/300 Models)
111
18 Service Work on the Engine
113
Checking the Gear Oil Level
113
Changing the Gear Oil
113
Draining the Gear Oil
114
Refilling with Gear Oil
114
Adding Gear Oil
115
19 Cleaning, Care
117
Cleaning the Motorcycle
117
Checks and Maintenance Steps for Winter Operation
118
20 Storage
119
Preparing for Use after Storage
119
21 Troubleshooting
120
22 Technical Data
122
Engine
122
All 125 Models
122
All 200 Models
122
All 250 Models
123
All 300 Models
123
Engine Tightening Torques
124
All 125/200 Models
124
All 250/300 Models
125
Capacities
126
Gear Oil
126
Coolant
126
Fuel
126
Chassis
126
Electrical System
127
Tires
128
Fork
128
EXC EU, All 200 Models
128
250/300 Exc Eu/Au, XC-W Us, 300 Exc Br
128
EXC Six Days EU
129
250/300 Six Days
129
Shock Absorber
130
All 125/200 Models
130
All 250/300 Models
130
Chassis Tightening Torques
131
Carburetor
133
22.10.1 All 125 Models
133
22.10.2 200 Exc Eu
133
22.10.3 200 Exc Au
133
22.10.4 200 XC-W Us
133
22.10.5 250 EXC EU, 250 EXC Six Days EU
134
22.10.6 250 Exc Au
134
22.10.7 250 XC-W Us
134
22.10.8 300 EXC EU, 300 EXC Six Days EU
134
22.10.9 300 Exc Au
135
22.10.10 300 Exc Br
135
22.10.11 300 XC-W US, 300 XC-W Six Days US
135
23 Carburetor Tuning
136
Carburetor Tuning
136
Carburetor Tuning (All 125 Models)
136
Carburetor Tuning (All 200 Models)
137
Carburetor Tuning (All 200 Models)
138
Carburetor Tuning (All 250 Models)
139
Carburetor Tuning (All 300 EXC Eu/Au/Six Days, 300 XC-W Us/Six Days)
140
Carburetor Tuning (300 EXC BR)
141
General Carburetor Tuning
142
24 Substances
143
25 Auxiliary Substances
146
26 Standards
148
27 List of Abbreviations
149
28 Lisy of Symbols
150
Yellow and Orange Symbols
150
Green and Blue Symbols
150
Index
151
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KTM 200 EXC Specifications
General
Starter
Kickstarter
Transmission
6-speed
Front Brake
Disc brake
Rear Brake
Disc brake
Cooling System
Liquid-cooled
Engine Type
2-stroke
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