KTM 200 EXC - Page 2

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Table of Contents

Default Chapter4
- Table of Contents4
1 Means of Representation7
- Symbols Used7
- Formats Used7
2 Safety Advice8
- Use Definition - Intended Use8
- Degrees of Risk and Symbols8
- Tampering Warning8
- Safe Operation9
- Protective Clothing9
- Work Rules9
- Environment9
- Owner's Manual9
3 Important Notes10
- Guarantee, Warranty10
- Operating and Auxiliary Substances10
- Spare Parts, Accessories10
- Service10
- Figures10
- Customer Service10
4 View of Vehicle11
- View of Vehicle, Front Left (Example)11
- View of Vehicle, Rear Right (Example)12
5 Serial Numbers13
- Chassis Number13
- Type Label13
- Key Number (All EXC Models)13
- Engine Number13
- Fork Part Number13
- Shock Absorber Part Number14
6 Controls15
- Clutch Lever15
- Hand Brake Lever15
- Throttle Grip15
- 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 Cap18
- Closing the Filler Cap18
- Fuel Tap19
- Choke19
- Shift Lever19
- Kick Starter20
- Foot Brake Lever20
- Side Stand20
- Steering Lock (All EXC Models)20
- Locking the Steering (All EXC Models)21
- Unlocking the Steering (All EXC Models)21
7 Speedometer22
- Speedometer Overview22
- Activation and Test22
- Setting Kilometers or Miles22
- Setting the Speedometer Functions23
- Setting the Clock23
- Viewing the Lap Time23
- Display Mode SPEED (Speed)24
- Display Mode SPEED/H (Service Hours)24
- Setup Menu25
- Setting the Unit of Measurement25
- Display Mode SPEED/CLK (Time)26
- Setting the Clock26
- Display Mode SPEED/LAP (Lap Time)26
- Viewing the Lap Time27
- 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 Functions30
- Table of Conditions and Menu Activation31
8 Preparing for Use32
- Advice on First Use32
- Running in the Engine33
- Preparing the Vehicle for Difficult Riding Conditions33
- Preparations for Riding on Dry Sand34
- Preparations for Riding on Wet Sand34
- Preparations for Riding on Wet and Muddy Surfaces35
- Preparations for Riding at High Temperatures and Low Speeds35
- Preparing for Riding at Low Temperatures or in Snow36
9 Riding Instructions37
- Checks and Maintenance Work When Preparing for Use37
- Starting37
- Start off38
- Shifting, Riding38
- Braking38
- Stopping, Parking39
- Transport39
- Refueling40
10 Service Schedule41
- Service Work (as Additional Order)42
11 Tuning the Chassis43
- Checking the Basic Chassis Setting with the Rider's Weight43
- Compression Damping of Shock Absorber43
- Adjusting the Low-Speed Compression Damping of the Shock Absorber43
- Adjusting the High-Speed Compression Damping of the Shock Absorber44
- Adjusting the Rebound Damping of the Shock Absorber44
- Measuring the Sag of the Unloaded Rear Wheel45
- Checking the Static Sag of the Shock Absorber45
- Checking the Riding Sag of the Shock Absorber46
- Adjusting the Spring Preload of the Shock Absorber46
- Adjusting the Riding Sag47
- Checking the Basic Setting of the Fork47
- Adjusting the Compression Damping of the Fork48
- Adjusting the Rebound Damping of the Fork49
- Adjusting the Spring Preload of the Fork (EXC, XC-W)50
- Handlebar Position51
- Adjusting the Handlebar Position52
12 Service Work on the Chassis54
- Raising the Motorcycle with the Lift Stand54
- Removing the Motorcycle from the Lift Stand54
- Bleeding the Fork Legs54
- Cleaning the Dust Boots of the Fork Legs55
- Removing the Fork Protector55
- Installing the Fork Protector56
- Removing the Fork Legs56
- Installing the Fork Legs57
- 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 Clamp59
- (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 Bearing64
- Adjusting the Play of the Steering Head Bearing65
- Greasing the Steering Head Bearing66
- Removing the Front Fender66
- Installing the Front Fender67
- Removing the Shock Absorber67
- Installing the Shock Absorber67
- Removing the Seat68
- Mounting the Seat68
- Removing the Air Filter Box Lid69
- Installing the Air Filter Box Lid69
- Removing the Air Filter69
- Installing the Air Filter70
- Cleaning the Air Filter and Air Filter Box70
- Sealing the Air Filter Box71
- Removing the Main Silencer71
- Installing the Main Silencer71
- Changing the Glass Fiber Yarn Filling of the Main Silencer71
- Removing the Fuel Tank72
- Installing the Fuel Tank73
- Checking the Chain for Dirt74
- Cleaning the Chain74
- Checking the Chain Tension74
- Adjusting the Chain Tension75
- Checking the Chain, Rear Sprocket, Engine Sprocket and Chain Guide76
- Checking the Frame77
- Checking the Swingarm78
- Checking the Routing of the Throttle Cable78
- Checking the Rubber Grip79
- Additionally Securing the Rubber Grip79
- Adjusting the Basic Position of the Clutch Lever79
- Checking/Correcting the Fluid Level of the Hydraulic Clutch80
- Changing the Hydraulic Clutch Fluid80
- Removing the Engine Guard82
- Installing the Engine Guard82
13 Brake System83
- Checking the Free Travel of the Hand Brake Lever83
- 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 Discs84
- Checking the Front Brake Fluid Level84
- Adding Front Brake Fluid84
- Checking the Front Brake Linings85
- Changing the Front Brake Linings86
- Checking the Free Travel of Foot Brake Lever87
- Adjusting the Basic Position of the Foot Brake Lever87
- Checking the Rear Brake Fluid Level88
- Adding Brake Fluid for the Rear Brake89
- Checking the Rear Brake Linings89
- Changing the Brake Linings of the Rear Brake90
14 Wheels, Tires92
- Removing the Front Wheel92
- Installing the Front Wheel92
- Removing the Rear Wheel93
- Installing the Rear Wheel94
- Checking the Tire Condition94
- Checking the Tire Air Pressure95
- Checking the Spoke Tension95
15 Electrical System97
- 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 Headlight100
- Refitting the Headlight Mask with the Headlight100
- Changing the Headlight Bulb101
- Changing the Turn Signal Bulb (All EXC Models)101
- Checking the Headlight Setting102
- Adjusting the Headlight Range102
- Changing the Speedometer Battery103
16 Cooling System104
- Checking the Antifreeze and Coolant Level104
- Checking the Coolant Level105
- Draining the Coolant105
- Refilling with Coolant106
17 Tuning the Engine108
- Checking the Play in the Throttle Cable108
- Adjusting the Play in the Throttle Cable108
- Carburetor - Idle108
- Carburetor - Adjusting the Idle Speed109
- Emptying the Carburetor Float Chamber110
- Checking the Basic Position of the Shift Lever111
- Adjusting the Basic Position of the Shift Lever111
- 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 Engine113
- Checking the Gear Oil Level113
- Changing the Gear Oil113
- Draining the Gear Oil114
- Refilling with Gear Oil114
- Adding Gear Oil115
19 Cleaning, Care117
- Cleaning the Motorcycle117
- Checks and Maintenance Steps for Winter Operation118
20 Storage119
- Preparing for Use after Storage119
21 Troubleshooting120
22 Technical Data122
- Engine122
- All 125 Models122
- All 200 Models122
- All 250 Models123
- All 300 Models123
- Engine Tightening Torques124
- All 125/200 Models124
- All 250/300 Models125
- Capacities126
- Gear Oil126
- Coolant126
- Fuel126
- Chassis126
- Electrical System127
- Tires128
- Fork128
- EXC EU, All 200 Models128
- 250/300 Exc Eu/Au, XC-W Us, 300 Exc Br128
- EXC Six Days EU129
- 250/300 Six Days129
- Shock Absorber130
- All 125/200 Models130
- All 250/300 Models130
- Chassis Tightening Torques131
- Carburetor133
- 22.10.1 All 125 Models133
- 22.10.2 200 Exc Eu133
- 22.10.3 200 Exc Au133
- 22.10.4 200 XC-W Us133
- 22.10.5 250 EXC EU, 250 EXC Six Days EU134
- 22.10.6 250 Exc Au134
- 22.10.7 250 XC-W Us134
- 22.10.8 300 EXC EU, 300 EXC Six Days EU134
- 22.10.9 300 Exc Au135
- 22.10.10 300 Exc Br135
- 22.10.11 300 XC-W US, 300 XC-W Six Days US135
23 Carburetor Tuning136
- Carburetor Tuning136
- 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 Tuning142
24 Substances143
25 Auxiliary Substances146
26 Standards148
27 List of Abbreviations149
28 Lisy of Symbols150
- Yellow and Orange Symbols150
- Green and Blue Symbols150
- Index151

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